Fe-based metal sheet and manufacturing method thereof

ABSTRACT

A cast slab containing C: less than 0.02 mass % and made of an Fe-based metal of an α-γ transforming component is subjected to hot rolling at a temperature of an A3 point or higher and is subjected to α-region rolling at a temperature of 300° C. or higher and lower than the A3 point, and thereby a base metal sheet having a {100} texture in a surface layer portion is fabricated. Then, by performing a heat treatment under predetermined conditions, an Fe-based metal sheet is obtained in which a Z value is not less than 2.0 nor more than 200 when intensity ratios of respective {001}&lt;470&gt;, {116}&lt;6 12 1&gt;, and {223}&lt;692&gt; directions in a sheet plane by X-ray diffraction are set to A, B, and C respectively and Z =(A+0.97B)/0.98C is satisfied.

TECHNICAL FIELD

The present invention relates to an Fe-based metal sheet having a highaccumulation degree of {200} planes suitably used for magnetic cores andthe like of electric motors, power generators, and transformers andcapable of contributing to downsizing of these magnetic cores andreduction in energy loss, and a manufacturing method thereof. Thisapplication is based upon and claims the benefit of priority of theprior Japanese Patent Application No. 2011-100014, filed on Apr. 27,2011, the prior Japanese Patent Application No. 2011-101893, filed onApr. 28, 2011, and the prior Japanese Patent Application No.2012-070166, filed on Mar. 26, 2012, the entire contents of which areincorporated herein by reference.

BACKGROUND ART

Electrical steel sheets alloyed with silicon or/and the like have beenconventionally used for magnetic cores of electric motors, powergenerators, transformers, and the like. Among electrical steel sheets,non-oriented electrical steel sheets having relatively random crystalorientations can be manufactured at a low cost, to thus be used formotors, transformers, and the like of home electric appliances, and thelike in a multipurpose manner. The crystal orientations of thisnon-oriented electrical steel sheet are random, thus making itimpossible to obtain a high magnetic flux density. In contrast to this,grain-oriented electrical steel sheets having aligned crystalorientations can obtain a high magnetic flux density, to thus be appliedto high-end use for driving motors and the like of HV vehicles and thelike. However, in a manufacturing method of a grain-oriented electricalsteel sheet that is industrialized currently, a long-time heat treatmentis required, to thus increase the cost.

As above, in the non-oriented electrical steel sheet, a sufficientlyhigh magnetic flux density cannot be obtained, and in the grain-orientedelectrical steel sheet, the direction in which a high magnetic fluxdensity can be obtained is limited to one to two direction/directions.On the other hand, in HV vehicles, and the like, achievement of hightorque and downsizing are required, and there is a demand formanufacturing a metal sheet capable of obtaining a high magnetic fluxdensity in an in-plane circumferential direction thoroughly as a metalsheet to be used for core materials of driving motors, and the like.Thus, as methods other than the industrialized manufacturing method ofthe grain-oriented electrical steel sheet, there have been proposed atechnique of increasing an accumulation degree of a specific crystalorientation and various techniques of decreasing a core loss. However,in the technique described in Patent Literature 7, for example, it ispossible to increase an accumulation degree of {200} planes, butdirectionality to a specific orientation occurs, to thus have a highmagnetic flux density in a specific direction, but a high magnetic fluxdensity cannot be obtained in an in-plane circumferential directionthoroughly, and the like, resulting in that in a conventional technique,satisfactory properties are not necessarily obtained.

CITATION LIST Patent Literature

Patent Literature 1: Japanese Laid-open Patent Publication No. 10-168542

Patent Literature 2: Japanese Laid-open Patent Publication No.2006-45613

Patent Literature 3: Japanese Laid-open Patent Publication No.2006-144116

Patent Literature 4: Japanese Laid-open Patent Publication No. 10-180522

Patent Literature 5: Japanese Laid-open Patent Publication No. 01-252727

Patent Literature 6: Japanese Laid-open Patent Publication No. 07-173542

Patent Literature 7: International Publication Pamphlet No.WO2011/052654

SUMMARY OF INVENTION Technical Problem

Thus, an object of the present invention is to provide an Fe-based metalsheet that is likely to become magnetized in a sheet plane and furtherhas a texture capable of obtaining a high magnetic flux densitythoroughly in an in-plane circumferential direction, and a manufacturingmethod thereof.

Solution to Problem

The present inventors, as a result of earnest examination, found that anorientation ratio to a specific orientation is controlled with respectto an Fe-based metal of an iron sheet or the like, and thereby a <100>orientation in αFe is more densely and thoroughly distributed in a metalsheet plane to make it possible to obtain a high magnetic flux densitythoroughly in an in-plane circumferential direction.

Further, the present inventors conceived that in order to manufacturesuch an Fe-based metal sheet, a texture in which an accumulation degreeof {100} planes is increased is first formed in a surface layer portion,and at the time of γ-α transformation by the subsequent heat treatment,the texture is transformed while taking over its {100} texture. Then,they earnestly examined a method of forming the {100} texture in thesurface layer portion and achievement of high accumulation of {200}planes using the γ-α transformation.

As a result, it was found that when the Fe-based metal sheet ismanufactured from a slab by rolling, a rolling temperature and areduction ratio are optimized, thereby making it possible to form the{100} texture in at least the surface layer portion. Then, it was foundthat when the {100} texture in the surface layer portion is taken overby using the γ-αtransformation thereafter, a different metal except Feis made to diffuse beforehand from the surface and a diffused region isturned into an α-Fe phase, and thereby in the region turned into theα-Fe phase, the {100} texture is formed, and at the time of the γ-αtransformation, an accumulation degree of {200} planes in the α-Fe phasefurther generated by the transformation increases and the <100>orientation is distributed more densely and thoroughly, thereby makingit possible to obtain a high magnetic flux density in the in-planecircumferential direction thoroughly.

Further, the present inventors found that in the case of a large amountof C content being contained, when the C content is decreased bydecarburization annealing, the decarburization annealing is performedunder predetermined conditions, thereby also making it possible to formthe {100} texture in at least the surface layer portion, and in theFe-based metal sheet obtained finally, the <100> orientation isdistributed more densely and thoroughly, thereby making it possible toobtain a high magnetic flux density in the in-plane circumferentialdirection thoroughly.

The gist of the present invention made as a result of such examinationsis as follows.

(1) An Fe-based metal sheet, includes: at least one type offerrite-forming element except Fe, in which when intensity ratios ofrespective {001}<470>, {116}<6 12 1>, and {223}<692> directions in asheet plane by X-ray diffraction are set to A, B and C respectively andZ=(A+0.97B)/0.98C is satisfied, a Z value is not less than 2.0 nor morethan 200.

(2) The Fe-based metal sheet according to (1), in which theferrite-forming element diffuses from a surface to be alloyed with Fe.

(3) The Fe-based metal sheet according to (1) or (2), in which a layercontaining the ferrite-forming element is formed on at least one side ofsurfaces of the Fe-based metal sheet, and the ferrite-forming elementthat has diffused from part of the layer is alloyed with Fe.

(4) The Fe-based metal sheet according to (3), in which a thickness ofthe layer containing the ferrite-forming element is not less than 0.01μm nor more than 500 μm.

(5) The Fe-based metal sheet according to any one of (1) to (4), inwhich an accumulation degree of {200} planes is not less than 30% normore than 99%, and an accumulation degree of {222} planes is not lessthan 0.01% nor more than 30%.

(6) The Fe-based metal sheet according to any one of (1) to (5), inwhich the ferrite-forming element is one type of element or moreselected from a group consisting of Al, Cr, Ga, Ge, Mo, Sb, Si, Sn, Ta,Ti, V, W, and Zn.

(7) The Fe-based metal sheet according to any one of (1) to (6), inwhich at least a partial region including the surfaces of the Fe-basedmetal sheet is an α single phase region made of an α single phase basedcomponent, and a ratio of the α single phase region to a cross sectionof the Fe-based metal sheet is 1% or more.

(8) The Fe-based metal sheet according to any one of (1) to (7), inwhich a thickness of the Fe-based metal sheet is not less than 10 μm normore than 6 mm.

(9) The Fe-based metal sheet according to any one of (1) to (8), inwhich the α single phase region is formed on a front surface side and arear surface side of the Fe-based metal sheet, and a crystal grainstraddling the α single phase region on the front surface side and the αsingle phase region on the rear surface side is formed.

(10) A manufacturing method of an Fe-based metal sheet, includes:

performing hot rolling on a cast slab containing C: less than 0.02 mass% and made of an Fe-based metal of an α-γ transforming component at atemperature of an A3 point of the cast slab or higher to obtain ahot-rolled sheet;

performing α-region rolling on the hot-rolled sheet at a temperature ofhigher than 300° C. and lower than the A3 point of the cast slab toobtain a rolled sheet;

performing cold rolling on the rolled sheet to obtain a base metal sheethaving a thickness of not less than 10 μm nor more than 6 mm;

bonding a ferrite-forming element to one surface or both surfaces of thebase metal sheet;

heating the base metal sheet having had the ferrite-forming elementbonded thereto up to an A3 point of the base metal sheet; and

further heating the heated base metal sheet to a temperature of notlower than the A3 point of the base metal sheet nor higher than 1300° C.and holding the base metal sheet; and

cooling the heated and held base metal sheet to a temperature of lowerthan the A3 point of the base metal sheet.

(11) The manufacturing method of the Fe-based metal sheet according to(10), in which a reduction ratio in the α-region rolling is −1.0 or lessin terms of true strain, and the sum of the reduction ratio in theα-region rolling and a reduction ratio in the cold rolling is −2.5 orless in terms of true strain.

(12) The manufacturing method of the Fe-based metal sheet according to(10) or (11), in which

a reduction ratio in the hot rolling is −0.5 or less in terms of truestrain.

(13) A manufacturing method of an Fe-based metal sheet, includes:

heating a steel sheet containing C: not less than 0.02 mass % nor morethan 1.0 mass %, having a thickness of not less than 10 μm nor more than6 mm, and made of an Fe-based metal of an α-γ transforming component toa temperature of an A1 point or higher and a temperature at which astructure is turned into an α single phase when decarburization isperformed until C becomes less than 0.02 mass %, to obtain a base metalsheet that has been subjected to decarburization in a range of not lessthan 5 μm nor more than 50 μm in a depth direction from its surfaceuntil C becomes less than 0.02 mass %;

bonding a ferrite-forming element to one surface or both surfaces of thebase metal sheet;

heating the base metal sheet having had the ferrite-forming elementbonded thereto up to an A3 point of the base metal sheet; and

further heating the heated base metal sheet to a temperature of notlower than the A3 point of the base metal sheet nor higher than 1300° C.and holding the base metal sheet; and

cooling the heated and held base metal sheet to a temperature of lowerthan the A3 point of the base metal sheet.

(14) The manufacturing method of the Fe-based metal sheet according to(13), in which the steel sheet made of the Fe-based metal furthercontains Mn of 0.2 mass % to 2.0 mass %, and decarburization anddemanganization are performed in a combined manner.

(15) The manufacturing method of the Fe-based metal sheet according to(13) or (14), further includes:

performing carburization on a steel sheet containing C: less than 0.02mass %, having a sheet thickness of not less than 10 μm nor more than 6mm, and made of an Fe-based metal of an α-γ transforming component tocontrol C to not less than 0.02 mass % nor more than 1.0 mass %.

Advantageous Effects of Invention

According to the present invention, it is possible to manufacture anFe-based metal sheet capable of obtaining a high magnetic flux densitythoroughly in an in-plane circumferential direction.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a view for explaining a method of calculating an averagemagnetic flux density B50;

FIG. 2 is a conceptual diagram showing the relationship between a Zvalue and a ratio B50/Bs of the average magnetic flux density B50 to asaturation magnetic flux density Bs and a magnetic flux densitydifference ΔB;

FIG. 3A is a view schematically showing a structure of a cross sectionof a base metal sheet having a {100} texture formed in a surface layerportion;

FIG. 3B is a view schematically showing the structure of the crosssection of the base metal sheet having a different metal layer formed inthe surface layer portion;

FIG. 3C is a view schematically showing the structure of the crosssection of the base metal sheet in a temperature increasing process;

FIG. 3D is a view schematically showing the structure of the crosssection of the base metal sheet in a heating and holding process;

FIG. 3E is a view schematically showing the structure of the crosssection of the base metal sheet in a cooling process;

FIG. 4A is a view schematically showing the structure of the crosssection of the base metal sheet in a state of being held at atemperature of an A3 point or higher;

FIG. 4B is a view schematically showing the structure of the crosssection of the base metal sheet after cooling in the case when thedifferent metal layers are made to remain;

FIG. 4C is a view schematically showing the structure of the crosssection of the base metal sheet in the case when the base metal sheet isalloyed up to its center portion in a state of being held at thetemperature of the A3 point or higher;

FIG. 4D is a view schematically showing the structure of the crosssection of the base metal sheet after cooling in the case when the basemetal sheet is alloyed up to the center portion; and

FIG. 5 is a view schematically showing the structure of the crosssection of the base metal sheet in which a crystal grain becomes coarse.

DESCRIPTION OF EMBODIMENTS

Generally, an orientation of easy magnetization exists in α-Fe crystal,and when in a direction in which direction cosines between <100>, <010>,<001> orientations, (which will be called a [100] orientationgenerically), and the orientation are large, excitation is performed ina fixed magnetic field and magnetometry is performed, a high magneticflux density is likely to be obtained. On the other hand, when in adirection in which direction cosines with respect to a <111> orientationbeing an orientation of hard magnetization are large, excitation isperformed and magnetometry is performed, a high magnetic flux density isunlikely to be obtained. The present inventors found that more [100]orientations in the α-Fe crystal exist in a sheet plane and further theα-Fe crystal is controlled to a specific texture that is thoroughlydistributed in the sheet plane, and thereby direction cosines withrespect to the [100] orientation always become large in an arbitrarydirection in the metal sheet plane, and when a magnetic field is appliedin an arbitrary direction in the metal sheet plane and magnetometry isperformed, a high magnetic flux density can be obtained.

It is characterized in that a specific texture that an Fe-based metalsheet of the present invention has contains at least one type offerrite-forming element except Fe, in which when intensity ratios inrespective {001}<470>, {116}<6 12 1>, and {223}<692> directions in asheet plane by X-ray diffraction are set to A, B, and C respectively andZ=(A+0.97B)/0.98C is satisfied, a Z value is not less than 2.0 nor morethan 200.

Next, the previously described Z value will be explained.

The main orientations on which attention is focused in the presentinvention are {001}<470>, {116}<6 12 1>, and {223}<692>. When examiningthe state of a three-dimensional texture calculated by a vector method,the present inventors noticed that X-ray random intensity ratios in theabove-described three plane orientations change depending on a magneticproperty of a product, and learned that mathematizing this makes itpossible to quantify the relationship with a magnetic property of aproduct and reached the present invention.

The X-ray random intensity ratios of these respective orientations maybe obtained from a three-dimensional texture calculated by a vectormethod based on a pole figure of {110}, or may also be obtained from athree-dimensional texture calculated by a series expansion method usinga plurality (preferably three or more) of pole figures out of polefigures of {110}, {100}, {211}, and {310}. For the X-ray randomintensity ratios in the above-described respective crystal orientationsby the latter method, for example, intensities of (001)[4 −7 0], (116)[1−12 1], and (223)[6 −9 2] at a φ2=45° cross-section of thethree-dimensional texture may be used as they are.

Subsequently, there will be explained a reason for which the expressionof Z=(A+0.97B)/0.98C was found.

First, the intensity of the {001}<470> orientation is set to A. Thisorientation is in the {100} plane, so that direction cosines withrespect to the {100} plane are 1.0. In the {100} plane, the [100]orientation being the orientation of easy magnetization exists, and thusorientation of this plane in the metal sheet plane is advantageous forobtaining a high magnetic flux density in the metal sheet plane. Thus,the intensity A is weighted with the direction cosines of 1.0 in termsof the degree of contribution to improving a magnetic flux density to beset to one of parameters in the Z value.

Next, the intensity of the {116}<6 12 1> orientation is set to B. Anangular difference between this orientation and the {001} plane is 13.3°and direction cosines are 0.97. In the {001} plane as well, the [100]orientation being the orientation of easy magnetization exists, and thusorientation of this plane in the metal sheet plane is advantageous forobtaining a high magnetic flux density in the metal sheet plane. Forthis reason, the intensity B is weighted with the direction cosines of0.97 in terms of the degree of contribution to improving a magnetic fluxdensity to be set to one of parameters in the Z value.

Further, the intensity of the {223}<692> orientation is set to C. Anangular difference between the {223}<692> orientation and a {111} planeis 11.4° and direction cosines are 0.98. As described previously, in the{111} plane, the [100] orientation being the orientation of easymagnetization is not contained, and orientation of this plane in themetal sheet plane is disadvantageous for obtaining a high magnetic fluxdensity. Thus, the intensity C is set not to have the degree ofcontribution to improving a magnetic flux density, is put in the Z valueas a parameter that performs division, and is multiplied by 0.98 beingthe direction cosines with respect to the {111} plane as its weighting.

From the above thought, it was found that when the intensity ratios inthe respective {001}<470>, {116}<6 12 1>, and {223}<692> directions inthe metal sheet plane by X-ray diffraction are set to A, B, and Crespectively, the expression of Z=(A+0.978)/0.98C is created, and as theZ value is increased, a high magnetic flux density can be obtained whenexcitation is performed in the metal sheet plane to performmagnetometry.

Further, the present inventors were able to find from a large number ofexperiments that a special condition capable of obtaining a highmagnetic flux density in an arbitrary direction in the metal sheet planeis that the Z value is not less than 2.0 nor more than 200. They graspedthe fact that the Z value is limited to this range, and thereby the[100] orientation being the orientation of easy magnetization isthoroughly distributed in the metal sheet plane, but have not obtainedevidence making theoretical explanation of this phenomenon possible sofar.

The present inventors found that when the Z value is not less than 2.0nor more than 200, a ratio B50/Bs of an average magnetic flux densityB50 to a saturation magnetic flux density Bs becomes a high level of0.80 or more and a magnetic flux density difference ΔB measured in themetal sheet plane becomes a low level of 0.15 T or less. FIG. 2schematically shows this relationship.

When the Z value is less than 2.0, crystal orientation of α-Fe shows atendency to decrease the [100] orientations being the orientation ofeasy magnetization in the metal sheet plane. Alternately, it shows atendency that the distribution of the [100] orientations in the metalsheet plane becomes non-uniform. That is, the average magnetic fluxdensity B50 in the metal sheet plane becomes small and the ratio B50/Bsof the average magnetic flux density B50 to the saturation magnetic fluxdensity Bs becomes less than 0.8. Alternately, only the magnetic fluxdensity in a specific direction increases and the magnetic flux densitydifference ΔB becomes greater than 0.15 T. Thus, the Z value is set to2.0 or more in the present invention.

On the other hand, when the Z value exceeds 200, the increase in themagnetic flux density is saturated and an increase in uniformity of themagnetic flux density in the metal sheet plane is also saturated. Incontrast to this, in order to manufacture a metal sheet such that the Zvalue exceeds 200, a heat treatment time is prolonged, or the like,which becomes difficult industrially, and thus the condition of the Zvalue is set to 200 or less.

Here, FIG. 1 is a view for explaining a method of calculating theaverage magnetic flux density B50. A manufacturing method will bedescribed later, but it is found that α-region rolling is performed at800° C. and as a different metal, 2.6 mass % of Sn and 0.9 mass % of Alare used, and thereby in an obtainable Fe-based metal sheet having athickness of 0.2 mm, a high magnetic flux density can be obtainedthoroughly in an in-plane circumferential direction.

Here, in a metal sheet having a higher accumulation degree of {200}planes among textures of the Fe-based metal sheet of the presentinvention in which the Z value is not less than 2.0 nor more than 200, ahigher magnetic flux density can be obtained. Specifically, in a texturein which an accumulation degree of {200} planes in an α-Fe phase is notless than 30% nor more than 99% and an accumulation degree of {222}planes in the α-Fe phase is not less than 001% nor more than 30%, ahigher magnetic flux density can be obtained.

When the accumulation degree of the {200} planes is less than 30% or theaccumulation degree of the {222} planes is greater than 30%, the averagemagnetic flux density B50 tends to slightly decrease even though the Zvalue is in the present invention range. Further, in a metal sheet inwhich the accumulation degree of the {200} planes is greater than 99% orthe accumulation degree of the {222} planes is less than 0.01%, theincrease in the magnetic flux density B50 is saturated and a heattreatment time is prolonged, and the like, resulting in thatmanufacturing conditions become disadvantageous industrially.

Next, the manufacturing method of the previously described Fe-basedmetal sheet will be explained.

(First Embodiment)

As a manufacturing method of an Fe-based metal sheet in this embodiment,a rolling temperature and a reduction ratio are optimized, and thereby a{100} texture is formed in at least a surface layer portion of the metalsheet, a ferrite-forming element is made to diffuse into this partial orwhole region from its surface, and at the time of cooling, the wholeFe-based metal sheet is oriented in {100}. This makes it possible toobtain a high magnetic flux density in an arbitrary direction in a metalsheet plane.

This embodiment as above is based on the fact found by the presentinventors that {100} crystal grains in the texture formed in the surfacelayer portion preferentially grow at an A3 point or higher in a heatingprocess to be performed for the diffusion of the ferrite-formingelement, and further when the ferrite-forming element is made to diffuseinto the inner portion to make the Fe-based metal sheet alloyedtherewith and then cooling is performed, an accumulation degree of {200}planes in the sheet plane of the Fe-based metal sheet increases.

[Explanation of the Basic Principle of the First Embodiment of thePresent Invention]

First, the basic principle of this embodiment capable of obtaining ahigh accumulation degree of {200} planes will be explained based on FIG.3A to FIG. 3E.

(a) Manufacture of a Base Metal Sheet (Seeding of a Texture)

In a process in which a cast slab containing C: less than 0.02 mass %and made of an Fe-based metal of an α-γ transforming component isdecreased in thickness by rolling and thereby a metal sheet is obtained,hot rolling is performed at a sheet temperature of the A3 point orhigher, α-region rolling is performed at a sheet temperature of lowerthan the A3 point and 300° C. or higher, and further cold rolling isperformed to a predetermined sheet thickness. By this process, as shownin FIG. 3A, a base metal sheet 1 having an inner region 4 made of Fe inan α phase and having a {100} texture 2 in at least a surface layerportion 3 is obtained. Further, a seed of crystal that satisfies thecondition of the Z value is formed in a recrystallized texture by aparticular deformation slip.

(b) (Formation of a Second Layer)

Next, as shown in FIG. 3B, the ferrite-forming element such as Al, forexample, is bonded to one surface or both surfaces of the cold-rolledbase metal sheet 1 by using a vapor deposition method or the like toform a second layer 5.

(c) Saving of the Texture

Next, the base metal sheet 1 having had the ferrite-forming elementbonded thereto is heated to the A3 point of the base metal sheet 1 tomake the ferrite-forming element diffuse into the partial or wholeregion having the {100} texture 2 in the base metal sheet 1, to make thebase metal sheet 1 alloyed therewith. As shown in FIG. 3C, an alloyedregion 6 is transformed to the α phase from a γ phase to have an αsingle phase component. At this time, the alloyed region 6 istransformed while taking over orientation of the {100} texture 2 formedin the surface layer portion 3, so that a structure oriented in {100} isformed also in the alloyed region 6.

(d) Achievement of High Accumulation of the Texture

Next, the partially alloyed base metal sheet 1 is further heated to atemperature of not lower than the A3 point nor higher than 1300° C. andthe temperature is held. The region of the α single phase component isan α-Fe phase not undergoing γ transformation, and thus the {100}crystal grains are maintained as they are, the {100} crystal grainspreferentially grow in the region, and the accumulation degree of the{200} planes increases. Further, as shown in FIG. 3D, a region 8 nothaving the α single phase component is transformed to the γ phase fromthe α phase.

Further, when a holding time of the temperature after the heating isprolonged, the {100} crystal grains are united to preferentially grow tolarge {100} crystal grains 7. As a result, the accumulation degree ofthe {200} planes further increases. Further, with the diffusion of theferrite-forming element, the region 6 alloyed with the ferrite-formingelement is transformed to the α phase from the γ phase. At this time, inthe region adjacent to the region to be transformed, crystal grains inthe α phase oriented in {100} are already formed, and at the time of thetransformation to the α phase from the γ phase, the region 6 istransformed while taking over a crystal orientation of the adjacentcrystal grains in the α phase. Thereby, the holding time is prolongedand the accumulation degree of the {200} planes increases.

(e) Growth of the Texture

The base metal sheet is cooled to a temperature of lower than the A3point. At this time, as shown in FIG. 3E, a γ-Fe phase in an unalloyedinner region 10 is transformed to the α-Fe phase. This inner region 10is adjacent to the region in which the crystal grains in the α phaseoriented in {100} are already formed in a temperature region of the A3point or higher, and at the time of the transformation to the α phasefrom the γ phase, the inner region 10 is transformed while taking overthe crystal orientation of the adjacent crystal grains in the α phaseand larger crystal grains 9 in the α phase oriented in {100} are formed.Therefore, the accumulation degree of the {200} planes increases also inthe region. By this phenomenon, the high accumulation degree of the{200} planes can be obtained even in the unalloyed region.

When at the stage of the preceding state shown in FIG. 3D, thetemperature of the A3 point or higher is held until the whole metalsheet is alloyed, the structure having the high accumulation degree ofthe {200} planes is already formed in the whole metal sheet, and thusthe cooling is performed while the state when the cooling is started ismaintained.

In the above, the basic principle of this embodiment was explained, andthere will be further explained a limiting reason of each condition thatdefines the manufacturing method of this embodiment and preferableconditions of this embodiment.

[Fe-Based Metal to be the Base Material] (C Content)

In this embodiment, first, crystal grains oriented in {100} to serve asseeds for increasing the accumulation degree of the {200} planes in thesheet are formed in the surface layer portion of the base metal sheetmade of the Fe-based metal. Then, the γ-α transformation is made toprogress in the metal sheet while taking over a crystal orientation ofthe crystal grains in the α phase to serve as the seeds finally, tothereby increase the accumulation degree of the {200} planes of thewhole metal sheet. For this reason, the Fe-based metal used for the basemetal sheet has a composition of the α-γtransforming component. When theFe-based metal used for the base metal sheet has the α-γ transformingcomponent, the ferrite-forming element is made to diffuse into the metalsheet to make the metal sheet alloyed therewith, thereby making itpossible to form the region having the α single phase based component.

In this embodiment, the C content of the base metal sheet is set to lessthan 0.02 mass %. Further, in terms of a magnetic property of a productmetal sheet, the C content is preferably 0.01 mass % or less. Under thecondition of the C content being less than 0.02 mass %, theferrite-forming element is made to diffuse into the metal sheet to makethe metal sheet alloyed therewith, thereby making it possible to formthe region having the α single phase based component. Incidentally, C isa component to remain in a process of manufacturing the slab and theless C is, the more preferred it is in terms of the magnetic property,and thus its lower limit is not necessary needed, but it is preferablyset to 0.0001 mass % or more in terms of the cost of a refining process.

(Other Containing Elements)

In principle, being applicable to the Fe-based metal having the α-γtransforming component, this embodiment is not limited to the Fe-basedmetal in a specific composition range. Typical examples of the α-γtransforming component are pure iron, steel such as ordinary steel, andthe like. For example, it is a component containing pure iron or steelcontaining C of 1 ppm to less than 0.02 mass % as described above and abalance being composed of Fe and inevitable impurities as its base andcontaining an additive element as required. Instead, it may be siliconsteel of the α-γ transforming component having C: less than 0.02 mass %and Si: 0.1 mass % to 2.5 mass % as its basic component. Further, asother impurities, a trace amount of Ni, Cr, Al, Mo, W, V, Ti, Nb, B, Cu,Zr, Y, Hf, La, Ce, N, O, P, S, and/or the like are/is contained.Further, Al and Mn are added to increase electric resistance, to therebydecrease a core loss, and Co is added to increase the saturationmagnetic flux density Bs, to thereby increase a magnetic flux density,which are also included in the present invention range.

(Thickness of the Base Metal Sheet)

The thickness of the base metal sheet is set to not less than 10 μm normore than 6 mm. When the thickness is less than 10 μm, when the basemetal sheets are stacked to be used as a magnetic core, the number ofthe sheets to be staked is increased to increase gaps, resulting in thata high magnetic flux density cannot be obtained. Further, when thethickness exceeds 6 mm, it is not possible to make the {100} texturegrow sufficiently even though a reduction ratio of the α-region rollingis adjusted, resulting in that a high magnetic flux density cannot beobtained.

[Rolling Conditions]

In this embodiment, as described previously, the Fe-based metal having,in at least the surface layer portion, the crystal grains oriented in{100} to serve as the seeds for increasing the accumulation degree ofthe {200} planes in the metal sheet is used as a starting material. As amethod of achieving high accumulation of the {100} planes of the basemetal sheet, a method of performing α-region rolling in a process inwhich a cast slab is rolled to a sheet shape is used.

First, a cast slab containing C: less than 0.02 mass % and made of theFe-based metal of the α-γtransforming component such as a continuouscast slab or an ingot is prepared. Then, in a process in which the castslab is decreased in thickness by rolling to obtain the base metalsheet, first the hot rolling is performed at a temperature of the A3point or higher. Next, the α-region rolling is performed at atemperature of lower than the A3 point and higher than 300° C., andfurther the metal sheet is subjected to cold rolling to a predeterminedthickness, and thereby the base metal sheet having the {100} textureformed in the surface layer portion is obtained.

As for a reduction ratio in each of rolling processes to be performeduntil the base metal sheet is obtained from the cast slab, the totalreduction ratio in the α-region rolling is preferably set to −1.0 orless in terms of true strain and the sum of the total reduction ratio inthe α-region rolling and the total reduction ratio in the cold rollingis preferably set to −2.5 or less in terms of true strain. Conditionsother than these may create a possibility that the {100} texture cannotbe sufficiently formed in the surface layer portion. A method ofexpressing the reduction ratio by true strain E is expressed by thefollowing expression (1), where in each of the rolling processes, thethickness before the rolling is set to h0 and the thickness after therolling is set to h.ε=ln(h/h0)  (1)

When the sum of the total reduction ratio in the α-region rolling andthe total reduction ratio in the cold rolling is in the previouslydescribed preferred range, a deformed structure in which the {100}texture is formed by recrystallization can be provided to at least thevicinity of the surface layer portion of the base metal sheet.Particular crystal slip and crystal rotation to occur at these reductionratios are thought to occur. Thus, they are preferably in these ranges.

Further, as for the reduction ratio in each of the rolling processes tobe performed until the base metal sheet is obtained from the cast slab,the reduction ratio in the hot rolling is preferably −0.5 or less interms of true strain, thereby making it easier to obtain the higheraccumulation degree of the {200} planes. This results from the factfound by the present inventors that in order that desirable deformationshould be performed in the α-region rolling and the cold rolling,deformation in the hot rolling in a γ region is also closely affected.Thus, these ranges are preferred.

The region of the surface layer portion in which the {100} texture isformed preferably has 1 μm or more of a distance in a sheet thicknessdirection from the surface. Thereby, it is possible to bring theaccumulation degree of the {200} planes to 30% or more in the followingdiffusion treatment. The upper limit of the distance is not limited inparticular, but it is difficult to form the {100} texture in a region of500 am or more by rolling.

Incidentally, the measurement of the accumulation degree of the {200}planes can be performed by X-ray diffraction using a MoKα ray. To be inmore detail, in the α-Fe crystal, integrated intensities of 11orientation planes ({110}, {200}, {211}, {310}, {222}, {321}, {411},{420}, {332}, {521}, and {442}) parallel to a sample surface aremeasured for each sample, each measured value is divided by atheoretical integrated intensity of the sample having a randomorientation, and thereafter, a ratio of the intensity of {200} or {222}is obtained in percentage.

At this time, for example, the accumulation degree of the {200} planesis expressed by Expression (2) below.accumulation degree of {200}planes=[{i(200)/I(200)}/Σ{i(hkl)/I(hkl)}]×100  (2)

Here, i(hkl) is an actually measured integrated intensity of {hkl}planes in the measured sample, and I(hkl) is a theoretical integratedintensity of the {hkl} planes in the sample having the randomorientation. Further, Σ is the sum of the 11 orientation planes in theα-Fe crystal. Here, instead of the theoretical integrated intensity ofthe sample having the random orientation, actually measured values usingthe sample may be used.

[Different Metal]

Next, a different metal except Fe is made to diffuse into the base metalsheet manufactured by the above-described rolling processes to increasethe region of the {100} texture in the thickness direction of the steelsheet. As the different metal, the ferrite-forming element is used. As aprocedure, first, the different metal is bonded in a layered form as thesecond layer to one surface or both surfaces of the base metal sheetmade of the Fe-based metal of the α-γ transforming component. Then, aregion alloyed by having had elements of the different metal diffusethereinto is turned to have the α single phase based component and to beable to be maintained as not only the region transformed to the α phase,but also a seed oriented in {100} for increasing the accumulation degreeof the {200} planes in the metal sheet. As such a ferrite-formingelement, at least one type of Al, Cr, Ga, Ge, Mo, Sb, Si, Sn, Ta, Ti, V,W, and Zn can be used alone or in a combined manner.

As a method of bonding the different metal in a layered form to thesurface of the base metal sheet, there can be employed various methodssuch as a plating method of hot dipping, electrolytic plating, or thelike, a rolling clad method, a dry process of PVD, CVD, or the like, andfurther powder coating. As a method of efficiently bonding the differentmetal for industrially implementing the method, the plating method orthe rolling clad method is suitable.

The thickness of the different metal before the heating when thedifferent metal is bonded is preferably not less than 0.05 μm nor morethan 1000 μm. When the thickness is less than 0.05 μm, it is notpossible to obtain the sufficient accumulation degree of the {200}planes. Further, when the thickness exceeds 1000 μm, even when thedifferent metal layer is made to remain, its thickness becomes largerthan necessary.

[Heating and Diffusion Treatment]

The base metal sheet having had the ferrite-forming element as thedifferent metal bonded thereto is heated up to the A3 point of the basemetal sheet, to thereby make the ferrite-forming element diffuse intothe partial or whole region of the {100} texture formed in the surfacelayer portion of the base metal sheet to make the base metal sheetalloyed therewith. The region alloyed with the ferrite-forming elementis turned to have the α single phase component and the region istransformed to the α phase from the γ phase. At this time, the region istransformed while taking over the orientation of the {100} textureformed in the surface layer portion, and thus the structure oriented in{100} is formed also in the alloyed region. As a result, in the alloyedregion, a structure in which the accumulation degree of the {200} planesin the α-Fe phase becomes not less than 25% nor more than 50% and inaccordance with it, the accumulation degree of the {222} planes in theα-Fe phase becomes not less than 1% nor more than 40% is formed.

Then, the base metal sheet is further heated to a temperature of notlower than the A3 point nor higher than 1300° C. and the temperature isheld. The region alloyed already is turned into an α single phasestructure that is not transformed to the γphase, so that the crystalgrains in the {100} texture are maintained as they are, and in theregion, the crystal grains in the {100} texture preferentially grow andthe accumulation degree of the {200} planes increases. Further, theregion not having the α single phase component is transformed to the γphase.

Further, when the holding time is prolonged, the crystal grains in the{100} texture are united to one another to preferentially grow. As aresult, the accumulation degree of the {200} planes further increases.Further, with the further diffusion of the ferrite-forming element, theregion alloyed with the ferrite-forming element is transformed to the αphase from the γ phase. At this time, as shown in FIG. 4A, in theregions adjacent to the regions to be transformed, crystal grains 7 inthe α phase oriented in {100} are already formed, and at the time of thetransformation to the α phase from the γ phase, the regions alloyed withthe ferrite-forming element are transformed while taking over a crystalorientation of the adjacent crystal grains 7 in the α phase. By thesephenomena, the holding time is prolonged and the accumulation degree ofthe {200} planes increases. Further, as a result, the accumulationdegree of the {200} planes decreases.

Incidentally, in order to finally obtain the high accumulation degree ofthe {200} planes of 50% or more, it is preferred that the holding timeshould be adjusted to, at this stage, bring the accumulation degree ofthe {200} planes in the α-Fe phase to 30% or more and bring theaccumulation degree of the {200} planes in the α-Fe phase to 30% orless. Further, when the A3 point or higher is held until the whole metalsheet is alloyed, as shown in FIG. 4C, the α single phase structures areformed up to the center portion of the metal sheet and grain structuresoriented in {100} reach the center of the metal sheet.

A holding temperature after the temperature is increased is set to notlower than the A3 point nor higher than 1300° C. Even when the metalsheet is heated at a temperature higher than 1300° C., an effect withrespect to the magnetic property is saturated. Further, cooling may bestarted immediately after the temperature reaches the holdingtemperature (in the case, the temperature is held for 0.01 second orlonger substantially), or cooling may also be started after thetemperature is held for 600 minutes or shorter. Even when thetemperature is held for longer than 600 minutes, the effect issaturated. When this condition is satisfied, the achievement of highaccumulation of the seeds oriented in the {200} plane further progressesto make it possible to more securely bring the accumulation degree ofthe {200} planes in the α-Fe phase to 30% or more after the cooling.

[Cooling after the Heating and Diffusion Treatment]

After the diffusion treatment, when the cooling is performed while theregion that is not alloyed with the ferrite-forming element isremaining, as shown in FIG. 4B, at the time of the transformation to theα phase from the γ phase, the unalloyed region is transformed whiletaking over the crystal orientation of the regions in which the crystalgrains 9 in the α phase oriented in {100} are already formed. Thereby,the accumulation degree of the {200} planes increases, and the metalsheet having the texture in which the accumulation degree of the {200}planes in the α-Fe phase is not less than 30% nor more than 99% and theaccumulation degree of the {200} planes in the α-Fe phase is not lessthan 0.01% nor more than 30% is obtained, the crystal satisfying thecondition of the Z value grows, and a high magnetic flux density can beobtained in an arbitrary direction in the metal sheet plane.

Further, as shown in FIG. 4C, when the A3 point or higher is held untilthe whole metal sheet is alloyed, and the grain structures oriented in{100} reach the center of the metal sheet, as shown in FIG. 4D, themetal sheet is cooled as it is, and the texture in which the crystalgrains 9 oriented in {100} reach up to the center of the metal sheet canbe obtained. Thereby, the whole metal sheet is alloyed with thedifferent metal, and the metal sheet having the texture in which theaccumulation degree of the {200} planes in the α-Fe phase is not lessthan 30% nor more than 99% and the accumulation degree of the {222}planes in the α-Fe phase is not less than 0.01% nor more than 30% isobtained.

As above, the value of the accumulation degree of the {200} planes andthe remaining state of the different metal on the surface of the basemetal sheet change depending on the holding time of the temperature ofthe A3 point or higher and the holding temperature. The example shown inFIG. 4B is in a state where the grain structures oriented in {100} donot reach up to the center of the metal sheet, the different metal alsoremain on the surfaces, and an α single phase front surface side regionand an α single phase rear surface side region being the second layerare formed, but it is also possible to obtain the grain structuresoriented in {100} up to the center of the metal sheet and to alloy allthe second layers on the surfaces.

Incidentally, at the time of the cooling after the diffusion treatment,a cooling rate is preferably not less than 0.1° C./sec nor more than500° C./sec. When the cooling is performed in this temperature range,the growth of the seeds oriented in the {200} plane further progresses.

Further, when the second layers are made to remain on the obtainableFe-based metal sheet having a thickness of not less than 10 μm nor morethan 6 mm, the thickness of the second layer is preferably set to notless than 0.01 μm nor more than 500 μm. Further, a ratio of the α singlephase region alloyed at this stage is preferably 1% or more in a crosssection of the Fe-based metal sheet.

Further, at the time of cooling to a temperature of lower than the A3point in the state shown in FIG. 4A, an average cooling rate at the timeof cooling to the A3 point—50° C. from the A3 point may be set to 50°C./minute or less. When the cooling is performed at the cooling rate inthis range, the adjacent crystal grains oriented in {100} are united toone another to grow, and as shown in FIG. 5, a coarse crystal grain 11straddling part of an α single phase front surface side region 6 aadjacent to a front surface side second layer 5 a and straddling part ofan α single phase rear surface side region 6 b adjacent to a rearsurface side second layer 5 b is formed. When the average cooling ratefrom the A3 point to the A3 point—50° C. becomes greater than 50°C./minute, there is no sufficient time for growth of the crystal grain11, resulting in that an excellent core loss property cannot beobtained. On the other hand, the lower limit of the average cooling ratefrom the A3 point to the A3 point—50° C. is not limited, but the lowerlimit is preferably set to 1° C./minute in terms of the productivity.

Further, in order to obtain a more excellent core loss property, anaverage cooling rate at the time of cooling to the A3 point—10° C. fromthe A3 point is preferably set to 20° C./minute or less. On the otherhand, the lower limit of the average cooling rate from the A3 point tothe A3 point—10° C. is not limited, but the lower limit is preferablyset to 1° C./minute in terms of the productivity.

(Second Embodiment)

In the previously described first embodiment, there was explained themanufacturing method of the previously described Fe-based metal sheet byusing the cast slab containing C: less than 0.02 mass % and made of theFe-based metal of the α-γ transforming component. In contrast to this,in this embodiment, there will be explained a manufacturing method ofthe previously described Fe-based metal sheet by using a cast slabcontaining C: 0.02 mass % or more.

When the C content is large, a good magnetic property cannot beobtained, so that it is necessary to remove C by performingdecarburization annealing. Thus, the decarburization annealing isperformed under conditions to be explained below, thereby making itpossible to increase the accumulation degree of the {200} planes.

In the method of this embodiment, a {100} texture is formed in a surfacelayer portion of an Fe-based metal sheet by using γ-α transformationaccompanying decarburization (and further demanganization), andthereafter a ferrite-forming element is made to diffuse into a partialor whole decarburized region and further over the region from itssurface, and at the time of cooling, the whole Fe-based metal sheet ismade to be oriented in {100}.

This embodiment as above is based on the fact found by the presentinventors that {100} crystal grains in the texture formed in the surfacepreferentially grow at an A3 point or higher in a heating process to beperformed for the diffusion of the ferrite-forming element and furtherwhen the ferrite-forming element is made to diffuse into the innerportion to make the Fe-based metal sheet alloyed therewith and thencooling is performed, an accumulation degree of {200} planes in a sheetplane of the Fe-based metal sheet increases.

[Explanation of the Basic Principle of the Second Embodiment of thePresent Invention]

First, the basic principle of this embodiment capable of obtaining ahigh accumulation degree of {200} planes will be explained based on FIG.3A to FIG. 3D, by taking the case of decarburization as an example.

(a) Seeding of a Texture

When being decarburized until C becomes less than 0.02 mass %, theFe-based metal sheet containing C: 0.02 mass % or more and having acomposition of the α-γ transforming component is heated to a temperatureat which a structure is turned into an α single phase and to atemperature of a γ single phase or a two-phase region of a γ phase andan α phase (namely, a temperature of an A1 point or higher) todecarburize the surface layer portion of the Fe-based metal sheet untilC becomes less than 0.02 mass %. Thereby, the γ-α transformation is madeto occur in a process of the decarburization to turn the decarburizedsurface layer portion into the α phase.

At this time, the decarburization progresses the most in the <110>direction in the γ phase having large gaps between lattices, and in thisportion, the C concentration becomes less than 0.02% and thetransformation to the α phase occurs. A {110} plane in the γ phasebecomes the {100} plane when the γphase is turned into the α phase in aBCC structure, and thus in the α phase after the decarburization, the{100} plane is preferentially formed. Further, the growth, of thecrystal grains in the α phase formed in the surface, in the sheetthickness direction is slow because its rate is controlled by adecarburization rate, and thus the crystal grains in the α phase formedin the surface grow in a direction parallel to the sheet plane. Further,in the surface of the metal sheet, the {100} plane preferentially growsby taking surface energy as driving force. As a result, the wholesurface of the metal sheet becomes a structure oriented in {100}finally. By this process, as shown in FIG. 3A, a base metal sheet 1having an inner region 4 made of Fe in the α phase and having theaccumulation degree of the {200} planes in the decarburized regionbrought to 20% or more can be obtained. Further, a seed of crystal thatsatisfies the condition of the Z value is formed in the structure formedat the time of the decarburization by taking the surface energy asdriving force.

(b) (Formation of a Second Layer)

Next, as shown in FIG. 3B, the ferrite-forming element such as Al isbonded to one surface or both surfaces of the base metal sheet 1 afterthe decarburization by using a vapor deposition method or the like toform a second layer 5.

(c) Saving of the Texture

Next, the base metal sheet 1 having had the ferrite-forming elementbonded thereto is heated to the A3 point of the base metal sheet 1 tomake the ferrite-forming element diffuse into the partial or wholedecarburized region in the base metal sheet 1 to make the base metalsheet 1 alloyed therewith. Thereby, as shown in FIG. 3C, the α phase isformed in an alloyed region 6. Alternately, the ferrite-forming elementis made to diffuse into the inner portion over the decarburized regionto make the base metal sheet 1 alloyed therewith, and the alloyed regionis turned to have the α single phase component partially, and therebythe region is turned into the α phase. At this time, the region istransformed while taking over orientation of the region formed by thedecarburization, so that the structure oriented in {100} is formed alsoin the alloyed region 6. Further, the orientation in {100} is furtherincreased even in crystal grains turned into the α phase previously.Further, when the ferrite-forming element is made to diffuse and thecrystal is oriented, the seed of the crystal satisfying the condition ofthe Z value preferentially grows.

(d) Achievement of High Accumulation of the Texture

Next, the partially alloyed base metal sheet 1 is further heated to atemperature of not lower than the A3 point nor higher than 1300° C. andthe temperature is held. The region of the α single phase component isan α-Fe phase not undergoing γ transformation, and thus the {100}crystal grains are maintained as they are, the {100} crystal grainspreferentially grow in the region, and the accumulation degree of the{200} planes increases. Further, as shown in FIG. 3D, the region nothaving the α single phase component is transformed to the γ phase fromthe α phase.

Further, when a holding time of the temperature after the heating isprolonged, the {100} crystal grains are united to preferentially grow tolarge {100} crystal grains 7. As a result, the accumulation degree ofthe {200} planes further increases. Further, with the diffusion of Al,the region alloyed with Al is transformed to the α phase from the γphase. At that time, in the region adjacent to the region to betransformed, crystal grains in the α phase oriented in {100} are alreadyformed, and at the time of the transformation to the α phase from the γphase, the region is transformed while taking over a crystal orientationof the adjacent crystal grains in the α phase. Thereby, the holding timeis prolonged and the accumulation degree of the {200} planes increases.

(e) Growth of the texture

Next, the base metal sheet is cooled to a temperature of lower than theA 3point. At this time, as shown in FIG. 3E, a γ-Fe phase in anunalloyed inner region 10 is transformed to the α-Fe phase. This innerregion 10 is adjacent to the region in which the crystal grains in the αphase oriented in {100} are already formed in a temperature region ofthe A3point or higher, and at the time of the transformation to the αphase from the γ phase, the inner region 10 is transformed while takingover the crystal orientation of the adjacent crystal grains in the αphase and larger crystal grains 9 in the α phase oriented in {100} areformed. Therefore, the accumulation degree of the {200} planes increasesalso in the region (see the state shown in FIG. 3E). By this phenomenon,the high accumulation degree of the {200} planes can be obtained even inthe unalloyed region 10.

When at the stage of the preceding state shown in FIG. 3D, thetemperature of the A3 point or higher is held until the whole metalsheet is alloyed, the structure having the high accumulation degree ofthe {200} planes is already formed in the whole metal sheet, and thusthe cooling is performed while the state when the cooling is started ismaintained.

Further, in the above explained example, the Fe-based metal sheetcontaining C: 0.02 mass % or more is used, but when an Fe-based metalsheet containing C: less than 0.02 mass % is used, carburization isperformed before the decarburization to bring the C content in theregion to be decarburized to 0.02 mass % or more.

In the above, the basic constitution of this embodiment was explained,and there will be further explained a limiting reason of each conditionthat defines a manufacturing method of this embodiment and preferableconditions of this embodiment.

[Fe-Based Metal to be the Base Material] (C Content)

In this embodiment, first, crystal grains oriented in {100} to serve asseeds for increasing the accumulation degree of the {200} planes areformed in the surface of the base metal sheet made of the Fe-basedmetal. Then, the γ-α transformation is made to progress in the metalsheet while taking over a crystal orientation of the crystal grains inthe α phase to serve as the seeds finally, to thereby increase theaccumulation degree of the {200} planes of the whole metal sheet.

In this embodiment, the seeds of the crystal grains oriented in {100}are formed in the surface of the base metal sheet by structure controlusing the γ-α transformation accompanying decarburization ordemanganization. The Fe-based metal used for the base metal sheet has acomposition of the α-γtransforming component, and the C content in theregion to be decarburized is brought to 0.02 mass % or more.

Further, the Fe-based metal used for the base metal sheet has the α-γtransforming component, and the ferrite-forming element is made todiffuse into the metal sheet to make the metal sheet alloyed therewith,thereby making it possible to form a region having the α single phasebased component. Further, the C content in the region to be decarburizedis brought to 0.02 mass % or more, thereby making it possible to use theγ-αtransformation accompanying the decarburization.

For bringing the C content in the base metal sheet to 0.02 mass % ormore, there is a method of using a base metal sheet manufactured from amolten material adjusted to contain C: 0.02 mass % or more by undergoingcasting and rolling processes (a melting method). As another method,there is a method in which a base metal sheet having the C content ofless than 0.02 mass % is used and in a surface layer portion of the basemetal sheet, a region containing C: 0.02 mass % or more is formed bycarburization.

In the case of the melting method, the range of the C content is set tonot less than 0.02 mass % nor more than 1.0 mass %. When the C contentis less than 0.02 mass %, it is not possible to use the formation of a{200} texture using the γ-α transformation accompanying thedecarburization. Further, when the C content is more than 1.0% mass, along time is required for the decarburization. The preferred range ofthe C content is not less than 0.05 mass % nor more than 0.5 mass %.

In the case of the carburization method, the range of the C content ofthe Fe-based metal of which the base metal sheet is made is set to 1 ppmor more and less than 0.02 mass %. Then, the surface layer of thisFe-based metal is subjected to the carburization so that the Cconcentration may become not less than 0.02 mass % nor more than 1.0mass % in the same manner as that in the melting case.

Further, a carburizing range is set to a region down to a distance yfrom the surface, where the distance in a depth direction from thesurface is set to y. This distance y is not less than 5 μm nor more than50 μm. When the distance y is less than 5 μm, it is difficult to bringthe accumulation degree of the {200} planes to 30% or more in thediffusion treatment after the decarburization, so that the distance y isset to 5 μm or more. Further, when the distance becomes greater than 50μm, a long time is required for the carburization, and further a longtime is required also for the decarburization of the whole carburizedregion. Further, an obtainable effect is also saturated, so that thepreferred distance y is set to 50 μm or less. The carburizing method isnot limited in particular, and a well-known gas carburizing method orthe like may be performed.

Incidentally, the C content is preferably 0.005 mass % or less in termsof a magnetic property of a product metal sheet, so that in order tomanufacture a steel sheet excellent in a magnetic property, siliconsteel having the C content of 0.005 mass % or less is used to besubjected to carburization in a manner to have the above-described Cconcentration, which is advantageous for cost.

(Mn Content)

When Mn being an austenite stabilizing element is contained in theFe-based metal, it is possible to form seeds of crystal grains orientedin {100} by structure control using the γ-α transformation accompanyingdemanganization. The demanganization is performed together with thedecarburization, and thereby the surface layer portion is turned intothe α phase more efficiently and the accumulation degree of the {200}planes in a decarburized and demanganized region is more increased. Inorder to exhibit such a function, the Mn content before performing thedemanganization treatment is preferably set to 0.2 mass % or more.

The above-described structure control using the γ-α transformation canbe performed even by the decarburization alone, so that Mn does not haveto be contained. However, when Mn is contained, an effect of increasingelectric resistance to decrease a core loss is also obtained, and thusMn in a range of 2.0 mass % or less may also be contained according toneed even when no demanganization is performed. From the above point,the range of the Mn content when Mn is contained is preferably set to0.2 mass % to 2.0 mass %.

(Other Containing Elements)

In principle, being applicable to the Fe-based metal having the α-γtransforming component, this embodiment is not limited to the Fe-basedmetal in a specific composition range. Typical examples of the α-γtransforming component are pure iron, steel such as ordinary steel, andthe like. For example, it is a component containing pure iron or steelcontaining C of 1 ppm to 0.10 mass % as described above or furthercontaining Mn of 0.2 mass % to 2.0 mass % and a balance being composedof Fe and inevitable impurities as its base and containing an additiveelement as required. Instead, it may be silicon steel of the α-γtransforming component having C: 1.0 mass % or less and Si: 0.1 mass %to 2.5 mass % as its basic component. Further, as other impurities, atrace amount of Ni, Cr, Al, Mo, W, V, Ti, Nb, B, Cu, Co, Zr, Y, Hf, La,Ce, N, O, P, S, and/or the like are/is contained. Incidentally, Al andMn are added to increase electric resistance, to thereby decrease a coreloss and Co is added to increase the saturation magnetic flux densityBs, to thereby increase a magnetic flux density, which are also includedin the present invention range.

(Thickness of the Base Metal Sheet)

The thickness of the base metal sheet is set to not less than 10 μm normore than 6 mm. When the thickness is less than 10 μm, when the basemetal sheets are stacked to be used as a magnetic core, the number ofthe sheets to be staked is increased to increase gaps, resulting in thata high magnetic flux density cannot be obtained. Further, when thethickness is greater than 6 mm, it is not possible to make the {100}texture grow sufficiently after cooling after the diffusion treatment,resulting in that a high magnetic flux density cannot be obtained.

[Decarburization Treatment]

In the decarburization treatment for turning the surface layer portionof the base metal sheet into the α phase, the base metal sheet isdesirably heated in a decarburizing atmosphere to be decarburized in thefollowing manner.

(Temperature of the Decarburization Treatment)

The temperature of the decarburization treatment is set to a temperatureof the A1 point or higher and a temperature at which a structure isturned into an α single phase when the decarburization is performeduntil C becomes less than 0.02 mass %. The base metal sheet containingC: 0.02 mass % or more is heated to a temperature of a γ single phase ora two-phase region of a γ phase and an α phase (namely a temperature ofthe A1 point or higher) in order to make the γ-αtransformation occur bythe decarburization.

(Atmosphere of the Decarburization Treatment)

With regard to the decarburizing atmosphere, a conventionally knownmethod in manufacture of a grain-oriented electrical steel sheet can beemployed. For example, there is a method in which decarburization isfirst performed in a weak decarburizing atmosphere, in a vacuum of 1Torr or less, for example, or in a gas atmosphere of one type or two ormore types of H₂, He, Ne, Nr, Kr, Xe, Rn, and N₂ at a temperature oflower than (a dew point—20)° C., and next decarburization is performedin a strong decarburizing atmosphere, or in a gas atmosphere in which aninert gas, or CO and CO₂ is/are added to H₂ at a temperature of (a dewpoint—20)° C. or higher, for example. In this case, if thedecarburization is continued to the end in the weak decarburizingatmosphere, a long time is required.

(Period of Performing the Decarburization Treatment)

The period of performing the decarburization treatment is preferably notshorter than 0.1 minute nor longer than 600 minutes. When the period isshorter than 0.1 minute, it is difficult to bring the accumulationdegree of the {200} planes to 20% or more after the decarburization, andwhen the period is long so as to exceed 600 minutes, too much cost isneeded.

(Range of Performing the Decarburization Treatment)

The range of performing the decarburization treatment is a range down toa distance x, where the distance in the depth direction from the surfaceis set to x, and the distance x is not less than 5 μm nor more than 50μm. When the distance x is less than 5 μm, it is difficult to bring theaccumulation degree of the {200} planes to 30% or more in the diffusiontreatment after the decarburization. For this reason, the distance x inthe depth direction from the surface is set to 5 μm or more. Further,when the distance is greater than 50 μm, a long time is required for thedecarburization, and further the accumulation degree of the {200} planesis saturated, and thus it is not advantageous industrially. Thus, thedistance x is set to 50 μm or less.

(Other Decarburizing Methods)

Further, as described in Patent Literature 6, it is also possible that amaterial promoting decarburization is applied to a surface of a steelsheet as an annealing separating agent and this is wound around a coiland is subjected to coil annealing, to thereby form a decarburizedregion. Further, it is also possible that the above-described annealingseparating agent is applied to a surface of a steel sheet in α singlesheet form and the steel sheets are stacked to be subjected to annealingat the above-described temperature for a similar time, to thereby form adecarburized region.

(C Content after the Decarburization)

The C content after the decarburization is set to less than 0.02 mass %in order to obtain an α-phase single phase structure as described above.It is preferably 0.005 mass % or less in terms of the magnetic propertyof a product.

(Accumulation Degree of the {200} Planes after the Decarburization)

It is preferred that the accumulation degree of the {200} planes in thedecarburized region after the decarburization should become 20% or moreby performing the decarburization annealing under the above conditions.When the accumulation degree of the {200} planes is less than 20%, it isdifficult to bring the accumulation degree of the {200} planes to 30% ormore in the diffusion treatment to be performed subsequently. Further,the upper limit of the accumulation degree of the {200} planes ispreferably set to 99%. When it is greater than 99%, the magneticproperty deteriorates. The accumulation degree of the {200} planes isadjusted to fall within the above-described range by selecting theconditions of the decarburizing temperature, the decarburizing time, thedecarburizing atmosphere, and the like. Incidentally, the measurement ofthe accumulation degree of the plane in the above-described orientationplane can be performed by X-ray diffraction using a MoKα ray similarlyto the first embodiment.

[Demanganization Treatment]

In this embodiment, the decarburization treatment and thedemanganization treatment may also be used in combination by containingMn in the base metal sheet. The demanganization treatment is performedsimultaneously with the decarburization or subsequently to thedecarburization under the following conditions. Incidentally, asdescribed in Patent Literature 6, it is also possible to perform thedecarburization treatment and the demanganization treatmentsimultaneously in a state where steel sheets each have an annealingseparating agent containing a material promoting decarburization and amaterial promoting demanganization applied thereto to be staked.

(Temperature and Range of the Demanganization Treatment)

The temperature at which the demanganization treatment is performed isset to a temperature of the A1 point or higher similarly to thedecarburization. With regard to a demanganizing atmosphere, thedemanganization treatment may be performed under a reduced pressureatmosphere. Further, the period of performing the demanganizationtreatment is preferably set to fall within a range of not shorter than0.1 minute nor longer than 600 minutes similarly to the decarburization.

(Range of Performing the Demanganization Treatment)

The range of performing the demanganization treatment is a range down toa distance x, where the distance in the depth direction from the surfaceis set to x, and the distance x is preferably not less than 5 μm normore than 50 μm. When the distance x is less than 5 μm, it is difficultto bring the accumulation degree of the {200} planes to 30% or more inthe diffusion treatment after the demanganization. For this reason, thepreferred distance x in the depth direction from the surface is set to 5μm or more. Further, when the distance is greater than 50 μm, a longtime is required for the demanganization, and further the accumulationdegree of the {200} planes is saturated, and thus it is not advantageousindustrially. Thus, the preferred distance x is set to 50 μm or less.

(Accumulation Degree of the {200} Planes after the Demanganization)

It is preferred that the accumulation degree of the {200} planes in theregion having been subjected to the demanganization treatment shouldbecome 20% or more after the demanganization by performing thedecarburization annealing under the above conditions. When theaccumulation degree of the {200} planes is less than 20%, it isdifficult to bring the accumulation degree of the {200} planes to 30% ormore in the diffusion treatment to be performed subsequently. The upperlimit of the accumulation degree of the {200} planes is preferably setto 99%. When it is greater than 99%, the magnetic property deteriorates.

[Different Metal]

Next, a different metal except Fe is made to diffuse into the base metalsheet having had the surface layer portion turned into the α phase bythe decarburization to increase the region of the {100} texture in thethickness direction of the metal sheet. As the different metal, theferrite-forming element is used. As a procedure, first, the differentmetal is bonded in a layered form as the second layer to one surface orboth surfaces of the base metal sheet made of the Fe-based metal of theα-γ transforming component. Then, a region alloyed by having hadelements of the different metal diffuse thereinto is turned to have theα single phase based component and to be able to be maintained as notonly the region having been subjected to the decarburization (or furtherthe demanganization) to be transformed to the α phase, but also a seedoriented in {100} for increasing the accumulation degree of the {200}planes in the metal sheet. As such a ferrite-forming element, at leastone type of Al, Cr, Ga, Ge, Mo, Sb, Si, Sn, Ta, Ti, V, W, and Zn can beused alone or in a combined manner.

As a method of bonding the different metal in a layered form to thesurface of the base metal sheet, there can be employed various methodssuch as a plating method of hot dipping, electrolytic plating, or thelike, a rolling clad method, a dry process of PVD, CVD, or the like, andfurther powder coating. As a method of efficiently bonding the differentmetal for industrially implementing the method, the plating method orthe rolling clad method is suitable.

The thickness of the different metal before the heating when thedifferent metal is bonded is preferably not less than 0.05 μm nor morethan 1000 μm. When the thickness is less than 0.05 μm, it is notpossible to obtain the sufficient accumulation degree of the {200}planes. Further, when the thickness exceeds 1000 μm, even when thedifferent metal layer is made to remain, its thickness becomes largerthan necessary.

[Heating and Diffusion Treatment]

The base metal sheet having had the ferrite-forming element bondedthereto is heated up to the A3 point of the base metal sheet, to therebymake the ferrite-forming element diffuse into the partial or wholeregion in the base metal sheet to make the base metal sheet alloyedtherewith. The α phase is maintained in the region alloyed with theferrite-forming element. Alternately, the ferrite-forming element ismade to diffuse into the inner portion over the decarburized region tomake the base metal sheet alloyed therewith, and the alloyed region isturned to have the α single phase component partially, and thereby theregion is turned into the α phase. At this time, the region istransformed while taking over the orientation of the region formed bythe decarburization, so that the accumulation degree of the {200} planesfurther increases. As a result, in the alloyed region, a structure inwhich the accumulation degree of the {200} planes in the α-Fe phasebecomes not less than 25% nor more than 50% and in accordance with it,the accumulation degree of the {200} planes in the α-Fe phase becomesnot less than 1% nor more than 40% is formed.

Then, the base metal sheet is further heated to a temperature of notlower than the A3 point nor higher than 1300° C. and the temperature isheld. The region alloyed already is turned into an α single phasestructure that is not transformed to the γphase, so that the {100}crystal grains are maintained as they are, and in the region, thecrystal grains in the {100} texture preferentially grow and theaccumulation degree of the {200} planes increases. Further, the regionnot having the α single phase component is transformed to the γ phase.

Further, when the holding time is prolonged, the crystal grains in the{100} texture are united to one another to preferentially grow. As aresult, the accumulation degree of the {200} planes further increases.Further, with the further diffusion of the ferrite-forming element, theregion alloyed with the ferrite-forming element is transformed to the αphase from the γ phase. At this time, as shown in FIG. 4A, in theregions adjacent to the regions to be transformed, crystal grains 7 inthe α phase oriented in {100} are already formed, and at the time of thetransformation to the α phase from the γ phase, the regions alloyed withthe ferrite-forming element are transformed while taking over a crystalorientation of the adjacent crystal grains 7 in the α phase. Thereby,the holding time is prolonged and the accumulation degree of the {200}planes increases. Further, as a result, the accumulation degree of the{200} planes decreases.

Incidentally, in order to finally obtain the high accumulation degree ofthe {200} planes of 50% or more, it is preferred that the holding timeshould be adjusted to, at this stage, bring the accumulation degree ofthe {200} planes in the α-Fe phase to 30% or more and bring theaccumulation degree of the {200} planes in the α-Fe phase to 30% orless. Further, when the A3 point or higher is held until the whole metalsheet is alloyed, as shown in FIG. 4C, the α single phase structures areformed up to the center portion of the metal sheet and grain structuresoriented in {100} reach the center of the metal sheet.

A holding temperature after the temperature is increased is set to notlower than A3 point nor higher than 1300° C. Even when the metal sheetis heated at a temperature higher than 1300° C., an effect with respectto the magnetic property is saturated. Further, cooling may be startedimmediately after the temperature reaches the holding temperature, orcooling may also be started after the temperature is held for 6000minutes or shorter. When this condition is satisfied, the achievement ofhigh accumulation of the seeds oriented in the {200} plane furtherprogresses to make it possible to more securely bring the accumulationdegree of the {200} planes in the α-Fe phase to 30% or more after thecooling.

[Cooling after the Heating and Diffusion Treatment]

After the diffusion treatment, when the cooling is performed while theregion that is not alloyed with the ferrite-forming element isremaining, as shown in FIG. 4B, at the time of the transformation to theα phase from the γ phase, the unalloyed region is transformed whiletaking over the crystal orientation of the regions in which the crystalgrains 9 in the α phase oriented in {100} are already formed. Thereby,the accumulation degree of the {200} planes increases, and the metalsheet having the texture in which the accumulation degree of the {200}planes in the α-Fe phase is not less than 30% nor more than 99% and theaccumulation degree of the {200} planes in the α-Fe phase is not lessthan 0.01% nor more than 30% is obtained, the crystal satisfying thecondition of the Z value grows, and a high magnetic flux density can beobtained in an arbitrary direction in the metal sheet plane.

Further, as shown in FIG. 4C, when the A3 point or higher is held untilthe whole metal sheet is alloyed and the grain structures oriented in{100} reach the center of the metal sheet, as shown in FIG. 4D, themetal sheet is cooled as it is, and the texture in which the grainstructures oriented in {100} reach the center of the metal sheet can beobtained. Thereby, the whole metal sheet is alloyed with the differentmetal, and the metal sheet having the texture in which the accumulationdegree of the {200} planes in the α-Fe phase is not less than 30% normore than 99% and the accumulation degree of the {200} planes in theα-Fe phase is not less than 0.01% nor more than 30% is obtained.

As above, the value of the accumulation degree of the {200} planes andthe remaining state of the different metal on the surface of the basemetal sheet change depending on the holding time of the temperature ofthe A3 point or higher and the holding temperature. The example shown inFIG. 4B is in a state where the grain structures oriented in {100} donot reach up to the center of the metal sheet and the different metalalso remains on the surfaces, but it is also possible to obtain thegrain structures oriented in {100} up to the center of the metal sheetand to alloy all the second layers on the surfaces.

Incidentally, at the time of the cooling after the diffusion treatment,a cooling rate is preferably not less than 0.1° C./sec nor more than500° C./sec. When the cooling rate is less than 0.1° C./sec, a long timeis required for the cooling, which is not appropriate, and when thecooling rate is greater than 500° C./sec, the metal sheet is sometimesdeformed, and thus the cooling rate is preferably 500° C./sec or less.

Incidentally, when the second layers are made to remain on theobtainable Fe-based metal sheet having a thickness of not less than 10μm nor more than 6 mm, the thickness of the second layer is preferablyset to not less than 0.01 μm nor more than 500 μm. Further, a ratio ofthe α single phase region alloyed at this stage is preferably 1% or morein a cross section of the Fe-based metal sheet.

Further, it is also possible to form a structure as shown in FIG. 5, andin this case, an average cooling rate is set to satisfy the conditionsimilar to that of the first embodiment, and thereby the above can beachieved.

EXAMPLE

Next, there will be explained experiments conducted by the presentinventors. Conditions and the like in these experiments are examplesemployed for confirming the applicability and effects of the presentinvention, and the present invention is not limited to these examples.

Example 1

In this example, base metal sheets of No. 1 to No. 17 each made of acomponent A or B shown in Table 1 below were manufactured under variousrolling conditions, to then have various different metals appliedthereto as a second layer, and then Fe-based metal sheets werefabricated, of which the previously described Z value (=(A+0.97B)/0.98C) and the magnetic flux density difference ΔB wereexamined. Further, the relationship between various manufacturingconditions and an accumulation degree of {200} planes was also examined.Further, effects obtained by changing a starting temperature in ana-region rolling process were also examined in detail.

TABLE 1 COMPONENT A3 ELEMENT MASS % SERIES POINT C Si Mn Al P N S 0OTHER A 925 0.0008 0.3 0.3 0.5 0.0003 0.0002 <0.0004 0.0002 — B 10100.0012 1.1 0.8 0.1 0.0002 0.0003 <0.0004 0.0001 — C 915 0.0032 0.2 0.080.05 0.0001 0.0003 <0.0004 0.0001 — D 870 0.0041 0.1 1.5 0.2 0.00010.0002 <0.0004 0.0001 — E 942 0.0105 0.2 0.5 0.7 0.0001 0.0003 <0.00040.0001 Cr: 0.5

First, ingots each having the component A or B shown in Table 1 and abalance being composed of Fe and inevitable impurities were melted byvacuum melting. Then, these were used as rolling materials to be workedinto cold-rolled sheets (the base metal sheets) each having apredetermined thickness under conditions of hot rolling, α-regionrolling, and cold rolling shown in Table 2 below.

TABLE 2 α-REGION HOT ROLLING ROLLING START FINISH START FINISH BASETEMPER- THICK- TEMPER- THICK- REDUC- TEMPER- THICK- TEMPER- MATERIAL A3ATURE NESS ATURE NESS TION ATURE NESS ATURE No. COMPONENT POINT ° C. mm° C. mm RATIO ° C. mm ° C. 1 A 925 1150 250 1000 10 −3.22 950 10 920 2 A925 1150 250 1000 10 −3.22 920 10 830 3 A 925 1150 250 1000 10 −3.22 85010 830 4 A 925 1150 250 1000 10 −3.22 750 10 730 5 A 925 1150 250 100010 −3.22 650 10 640 6 A 925 1150 250 1000 10 −3.22 550 10 540 7 A 9251150 250 1000 10 −3.22 450 10 450 8 A 925 1150 250 1000 10 −3.22 300 10350 9 A 925 1150 250 1000 10 −3.22 250 10 250 10 B 1010 1200 280 1050 50−1.72 1050 50 980 11 B 1010 1200 280 1050 50 −1.72 950 50 880 12 B 10101200 280 1050 50 −1.72 850 50 770 13 B 1010 1200 280 1050 50 −1.72 75050 660 14 B 1010 1200 280 1050 50 −1.72 600 50 580 15 B 1010 1200 2801050 50 −1.72 450 50 485 16 B 1010 1200 280 1050 50 −1.72 300 50 390 17B 1010 1200 280 1050 50 −1.72 250 50 230 α-REGION ROLLING COLD ROLLINGFINISH START FINISH TOTAL REDUCTION BASE THICK- REDUC- THICK- THICK-REDUC- REDUC- RATIO OF α MATERIAL NESS TION NESS NESS TION TION REGION +No. min RATIO mm mm RATIO RATIO COLD ROLLING 1 2.5 −1.39 2.5 0.2 −2.53−7.13 −3.91 2 2.5 −1.39 2.5 0.2 −2.53 −7.13 −3.91 3 2.5 −1.39 2.5 0.2−2.53 −7.13 −3.91 4 2.5 −1.39 2.5 0.2 −2.53 −7.13 −3.91 5 2.5 −1.39 2.50.2 −2.53 −7.13 −3.91 6 2.5 −1.39 2.5 0.2 −2.53 −7.13 −3.91 7 2.5 −1.392.5 0.2 −2.53 −7.13 −3.91 8 2.5 −1.39 2.5 0.2 −2.53 −7.13 −3.91 9 2.5−1.39 2.5 0.2 −2.53 −7.13 −3.91 10 3.0 −2.81 3.0 0.5 −1.79 −6.33 −4.6111 3.0 −2.81 3.0 0.5 −1.79 −6.33 −4.61 12 3.0 −2.81 3.0 0.5 −1.79 −6.33−4.61 13 3.0 −2.81 3.0 0.5 −1.79 −6.33 −4.61 14 3.0 −2.81 3.0 0.5 −1.79−6.33 −4.61 15 3.0 −2.81 3.0 0.5 −1.79 −6.33 −4.61 16 3.0 −2.81 3.0 0.5−1.79 −6.33 −4.61 17 3.0 −2.81 3.0 0.5 −1.79 −6.33 −4.61

In the case of the component A, the ingots each having a thickness of250 mm heated to 1150° C. were first subjected to hot rolling at areduction ratio of −3.22 in terms of true strain, and hot-rolled sheetseach having a thickness of 10 mm were obtained. Next, these hot-rolledsheets were each subjected to α-region rolling at a reduction ratio of−1.39 in terms of true strain at a temperature of 300 to 1000° C. Theserolled sheets obtained by the α-region rolling were pickled, and thenthe base metal sheets were obtained by cold rolling. At this time, thereduction ratio was −2.53 in terms of true strain, and as a result, thethickness of each of the obtained base metal sheets was 0.2 mm.

In the case of the component B, the ingots each having a thickness of280 mm heated to 1200° C. were first subjected to hot rolling at areduction ratio of −1.72 in terms of true strain, and hot-rolled sheetseach having a thickness of 50 mm were obtained. Next, these hot-rolledsheets were each subjected to α-region rolling at a reduction ratio of−2.81 in terms of true strain at a temperature of 300 to 1050° C. Theserolled sheets obtained by the α-region rolling were pickled, and thenthe base metal sheets were obtained by cold rolling. At this time, thereduction ratio was −1.79 in terms of true strain, and as a result, thethickness of each of the obtained base metal sheets was 0.5 mm.

With respect to the base metal sheets obtained by the above procedure, atexture of a surface layer portion of each of the base materials wasmeasured by X-ray diffraction to obtain an accumulation degree of {200}planes and an accumulation degree of {222} planes by the previouslydescribed method. Further, thinning was performed so that a structurecould be observed from a direction perpendicular to an L cross section,and a region up to ¼t (t represents a thickness) from the surface wasobserved. The main phase of each of the obtained base metal sheets atroom temperature was an α-Fe phase. Further, as a result of measurement,the A3 point at which the α-γ transformation occurred was 925° C. in thecomponent A and 1010° C. in the component B.

Next, both surfaces of each of the base metal sheets of No. 1 to No. 17shown in Table 2 were coated with each of various different metalelements as the second layer by a vapor deposition method, a sputteringmethod, or an electroplating method. As shown in Table 3 and Table 4below, as the different metal element, any one of Al, Si, Mo, Ga, Sn,Ti, Ge, Sb, V, and W was selected. The thickness of each of the coatingswas as shown in Table 3 and Table 4.

Next, an experiment was performed in which a heat treatment wasperformed on the base metal sheets to each of which the second layerswere bonded under various conditions. A gold image furnace was used forthe heat treatment, and a holding time was controlled by programcontrol. During which the temperature increased to be held, the heattreatment was performed in an atmosphere vacuumed to a pressure of 10⁻³Pa level. At the time of cooling, in the case of a cooling rate of 1°C./sec or lower, temperature control was performed in a vacuum byfurnace output control. Further, in the case of the cooling rate of 10°C./sec or more, an Ar gas was introduced and the cooling rate wascontrolled by adjustment of its flow rate.

Here, there was examined a change in the texture among a temperatureincreasing process of heating up to the A3 point, a holding process ofheating to a temperature of not lower than the A3 point nor higher than1300° C. and holding the temperature, and a cooling process of coolingto a temperature of lower than the A3 point. Specifically, three basemetal sheets with the same combination of the base material-coatingconditions were prepared, of which a change in the texture was examinedby performing a heat treatment experiment in each of the processes.

A sample for the temperature increasing process was fabricated in such amanner that the base metal sheet was heated from room temperature to theA3 point at a predetermined temperature increasing rate and was cooledto room temperature without any holding time. The cooling rate was setto 100° C./sec. The texture was measured by the method using thepreviously described X-ray diffraction method, and the X-ray was emittedfrom its surface, and the accumulation degree of {200} planes in theα-Fe phase and the accumulation degree of {222} planes in the α-Fe phasewere obtained in an inverse pole figure.

A sample for the holding process was fabricated in such a manner thatthe base metal sheet was heated from room temperature to a predeterminedtemperature over the A3 point at a predetermined temperature increasingrate and was cooled to room temperature after a predetermined holdingtime. Then, the texture of the fabricated sample was measured in thesame manner, and the accumulation degrees of {200} and {222} planes inthe α-Fe phase were obtained.

A sample for the cooling process was fabricated in such a manner thatthe base metal sheet was heated from room temperature to a predeterminedtemperature over the A3 point at a predetermined temperature increasingrate and was cooled to room temperature at a predetermined cooling rateafter a predetermined holding time. Further, in order to evaluate theaccumulation degrees of {200} and {222} planes at an unalloyed position,a test piece was fabricated by removing a layer from the surface of thefabricated sample to a predetermined distance so that the unalloyedposition might become an evaluation surface. Incidentally, when thewhole metal sheet was alloyed, the evaluation surface was set to aposition of ½ of the sheet thickness. With regard to the measurement ofthe texture of the fabricated sample, the X-ray was emitted from thesurface of the test piece and from a predetermined surface of the testpiece from which the layer was removed, and the accumulation degrees of{200} and {200} planes in the α-Fe phase of the surfaces were obtainedin the same manner.

Next, magnetometry was performed in order to evaluate obtained products.First, the average magnetic flux density B50 to a magnetizing force of5000 A/m and the magnetic flux density difference ΔB were obtained byusing a SST (Single Sheet Tester). At this time, a measurement frequencywas set to 50 Hz. When the average magnetic flux density B50 wasobtained, as shown in FIG. 1, the magnetic flux density B50 was obtainedevery 22.5° in a circumferential direction of the product and an averagevalue of the magnetic flux densities B50 in these 16 directions wascalculated. Further, of the magnetic flux densities B50 in these 16directions, the difference between the maximum value and the minimumvalue was set to the magnetic flux density difference ΔB. Next, thesaturation magnetic flux density Bs was obtained by using a VSM(Vibrating Sample Magnetometer). The magnetizing force applied at thistime was 0.8×10⁶ A/m. An evaluation value was set to the ratio B50/Bs ofthe average magnetic flux density B50 to the saturation magnetic fluxdensity.

Further, by the previously described X-ray diffraction, intensity ratiosof {001}<470>, {116}<6 12 1>, and {223}<692> were calculated, andthereby the previously described Z value was calculated.

Table 3 and Table 4 below show the accumulation degrees of the {200}planes and the accumulation degrees of the {222} planes measured in therespective processes during the manufacture and after the manufacture,the Z values of the obtained Fe-based metal sheets, and evaluationresults of the magnetometry.

TABLE 3 MANUFACTURE SEEDING BASE SEEDING SEEDING MATERIAL SECOND LAYERTEMPERATURE ACCUMULATION ACCUMULATION THICK- THICK- INCREASING DEGREE OFDEGREE OF NESS NESS BONDING RATE MEASURED {200} PLANES {222} PLANES No.No. mm ELEMENT μm METHOD ° C./sec TEMPERATURE IN αFe IN αFe 1 1 0.2 Al 4VAPOR 20 925 14 13 DEPOSITION 2 2 0.2 Al 4 VAPOR 20 925 19 12 DEPOSITION3 3 0.2 Al 4 VAPOR 20 925 25 10 DEPOSITION 4 4 0.2 Al 4 VAPOR 20 925 279.6 DEPOSITION 5 5 0.2 Al 4 VAPOR 20 925 33 9.1 DEPOSITION 6 6 0.2 Al 4VAPOR 20 925 34 8.8 DEPOSITION 7 7 0.2 Al 4 VAPOR 20 925 35 8.7DEPOSITION 8 8 0.2 Al 4 VAPOR 20 925 28 9.5 DEPOSITION 9 9 0.2 Al 4VAPOR 20 925 27 9.8 DEPOSITION 10 1 0.2 Si 5 SPUTTERING 70 925 14 13 112 0.2 Si 5 SPUTTERING 70 925 18 12 12 3 0.2 Si 5 SPUTTERING 70 925 26 1013 4 0.2 Si 5 SPUTTERING 70 925 27 9.4 14 5 0.2 Si 5 SPUTTERING 70 92532 8.8 15 6 0.2 Si 5 SPUTTERING 70 925 35 8.2 16 7 0.2 Si 5 SPUTTERING70 925 35 8.3 17 8 0.2 Si 5 SPUTTERING 70 925 29 9.7 18 9 0.2 Si 5SPUTTERING 70 925 28 10 19 1 0.2 Mo 1.5 SPUTTERING 10 925 15 12 20 2 0.2Mo 1.5 SPUTTERING 10 925 17 11 21 3 0.2 Mo 1.5 SPUTTERING 10 925 26 9.822 4 0.2 Mo 1.5 SPUTTERING 10 925 28 9.2 23 5 0.2 Mo 1.5 SPUTTERING 10925 33 8.6 24 6 0.2 Mo 1.5 SPUTTERING 10 925 35 8.3 25 7 0.2 Mo 1.5SPUTTERING 10 925 36 8.1 26 8 0.2 Mo 1.5 SPUTTERING 10 925 27 10 27 90.2 Mo 1.5 SPUTTERING 10 925 26 11 28 1 0.2 Ga 3 VAPOR 0.5 925 15 13DEPOSITION 29 2 0.2 Ga 3 VAPOR 0.5 925 17 12 DEPOSITION 30 3 0.2 Ga 3VAPOR 0.5 925 26 10 DEPOSITION 31 4 0.2 Ga 3 VAPOR 0.5 925 28 9.3DEPOSITION 32 5 0.2 Ga 3 VAPOR 0.5 925 34 8.7 DEPOSITION 33 6 0.2 Ga 3VAPOR 0.5 925 35 8.1 DEPOSITION 34 7 0.2 Ga 3 VAPOR 0.5 925 35 7.8DEPOSITION 35 8 0.2 Ga 3 VAPOR 0.5 925 27 10 DEPOSITION 36 9 0.2 Ga 3VAPOR 0.5 925 25 11 DEPOSITION 37 1 0.2 Sn 6 ELECTROLYTiC 5 925 16 13PLATING 38 2 0.2 Sn 6 ELECTROLYTIC 5 925 19 11 PLATING 39 3 0.2 Sn 6ELECTROLYTIC 5 925 27 9.5 PLATING 40 4 0.2 Sn 6 ELECTROLYTIC 5 925 289.1 PLATING 41 5 0.2 Sn 6 ELECTROLYTIC 5 925 32 8.7 PLATING 42 6 0.2 Sn6 ELECTROLYTIC 5 925 33 8.3 PLATING 43 7 0.2 Sn 6 ELECTROLYTIC 5 925 348.2 PLATING 44 8 0.2 Sn 6 ELECTROLYTIC 5 925 27 9.7 PLATING 45 9 0.2 Sn6 ELECTROLYTIC 5 925 26 11 PLATING MANUFACTURE SAVING AND ACHIEVEMENT OFHIGH ACCUMULATION ACHIEVEMENT ACHIEVEMENT OF HIGH OF HIGH ACCUMULATIONACCUMULATION GROWTH ACCUMULATION ACCUMULATION ½t ½t HOLDING HOLDINGDEGREE OF DEGREE OF COOLING ACCUMULATION ACCUMULATION TEMPERATURE TIME{200} PLANES {222} PLANES RATE DEGREE OF DEGREE OF No. ° C. sec IN αFeIN αFe ° C./sec {200} PLANES {222} PLANES 1 1000 20 16 13 150 16 13 21000 20 25 10.4 150 25 10.4 3 1000 20 30 9.1 150 30 9.1 4 1000 20 41 3.4150 41 3.4 5 1000 20 53 1.8 150 53 1.8 6 1000 20 52 2.1 150 52 2.1 71000 20 50 2.3 150 50 2.3 8 1000 20 38 3.8 150 38 3.8 9 1000 20 37 4.2150 37 4.2 10 1050 10 17 12 250 17 12 11 1050 10 24 12 250 24 12 12 105010 31 8.7 250 31 8.7 13 1050 10 42 3.2 250 42 3.2 14 1050 10 55 1.7 25055 1.7 15 1050 10 54 1.9 250 54 1.9 16 1050 10 51 2.2 250 51 2.2 17 105010 39 4.1 250 39 4.1 18 1050 10 37 4.5 250 37 4.5 19 1250 10 15 13 10 1513 20 1250 10 23 13 10 23 13 21 1250 10 30 9.3 10 30 9.3 22 1250 10 414.1 10 41 4.1 23 1250 10 52 2.4 10 52 2.4 24 1250 10 52 2.6 10 52 2.6 251250 10 51 2.9 10 51 2.9 26 1250 10 38 4.8 10 38 4.8 27 1250 10 37 5.510 37 5.5 28 980 100 17 11 50 17 11 29 980 100 27 9.8 50 27 9.8 30 980100 33 8.5 50 33 8.5 31 980 100 43 3.5 50 43 3.5 32 980 100 57 1.8 50 571.8 33 980 100 56 2.1 50 56 2.1 34 980 100 55 2.3 50 55 2.3 35 980 10040 3.9 50 40 3.9 36 980 100 37 4.5 50 37 4.5 37 1100 20 16 13 350 16 1338 1100 20 27 11 350 27 11 39 1100 20 32 9.4 350 32 9.4 40 1100 20 453.1 350 45 3.1 41 1100 20 58 1.4 350 58 1.4 42 1100 20 57 1.9 350 57 1.943 1100 20 56 2.1 350 56 2.1 44 1100 20 43 3.8 350 43 3.8 45 1100 20 415.1 350 41 5.1 PRODUCT TEXTURE EVALUATION ACCUMULATION ACCUMULATIONDEGREE OF DEGREE OF MAGNETIC {200} PLANES {222} PLANES FLUX DENSITYα-REGION No. IN αFe IN αFe Z B50 T Bs T B50/Bs ΔB T NOTE TEMPERATURE 116 13 1.2 1.60 2.05 0.78 0.070 COMPARATIVE 950 EXAMPLE 1 2 25 10.4 2.11.66 2.05 0.81 0.065 PRESENT 920 INVENTION EXAMPLE 1 3 30 9.1 5.8 1.712.05 0.83 0.060 PRESENT 850 INVENTION EXAMPLE 2 4 41 3.4 23 1.77 2.050.86 0.056 PRESENT 750 INVENTION EXAMPLE 3 5 53 1.8 160 1.84 2.05 0.900.018 PRESENT 650 INVENTION EXAMPLE 4 6 52 2.1 120 1.87 2.05 0.91 0.021PRESENT 550 INVENTION EXAMPLE 5 7 50 2.3 42 1.86 2.05 0.91 0.070 PRESENT450 INVENTION EXAMPLE 6 8 38 3.8 3.5 1.80 2.05 0.88 0.145 PRESENT 300INVENTION EXAMPLE 7 9 37 4.2 1.1 1.78 2.05 0.87 0.220 COMPARATIVE 250EXAMPLE 2 10 17 12 1.4 1.60 2.05 0.78 0.080 COMPARATIVE 950 EXAMPLE 3 1124 12 2.5 1.65 2.05 0.80 0.074 PRESENT 920 INVENTION EXAMPLE 8 12 31 8.73.8 1.66 2.05 0.81 0.070 PRESENT 850 INVENTION EXAMPLE 9 13 42 3.2 271.79 2.05 0.87 0.054 PRESENT 750 INVENTION EXAMPLE 10 14 55 1.7 156 1.882.05 0.92 0.015 PRESENT 650 INVENTION EXAMPLE 11 15 54 1.9 134 1.87 2.050.91 0.025 PRESENT 550 INVENTION EXAMPLE 12 16 51 2.2 51 1.86 2.05 0.910.036 PRESENT 450 INVENTION EXAMPLE 13 17 39 4.1 5.8 1.81 2.05 0.880.145 PRESENT 300 INVENTION EXAMPLE 14 18 37 4.5 1.7 1.74 2.05 0.850.210 COMPARATIVE 250 EXAMPLE 4 19 15 13 1.3 1.59 2.05 0.78 0.087COMPARATIVE 950 EXAMPLE 5 20 23 13 2.4 1.66 2.05 0.81 0.081 PRESENT 920INVENTION EXAMPLE 15 21 30 9.3 5.8 1.72 2.05 0.84 0.080 PRESENT 850INVENTION EXAMPLE 16 22 41 4.1 19 1.78 2.05 0.87 0.074 PRESENT 750INVENTION EXAMPLE 17 23 52 2.4 149 1.86 2.05 0.91 0.021 PRESENT 650INVENTION EXAMPLE 18 24 52 2.6 174 1.86 2.05 0.91 0.018 PRESENT 550INVENTION EXAMPLE 19 25 51 2.9 39 1.86 2.05 0.91 0.093 PRESENT 450INVENTION EXAMPLE 20 26 38 4.8 3.1 1.77 2.05 0.86 0.138 PRESENT 300INVENTION EXAMPLE 21 27 37 5.5 1.1 1.76 2.05 0.86 0.190 COMPARATIVE 250EXAMPLE 6 28 17 11 1.2 1.61 2.05 0.79 0.082 COMPARATIVE 950 EXAMPLE 7 2927 9.8 2.5 1.65 2.05 0.80 0.073 PRESENT 920 INVENTION EXAMPLE 22 30 338.5 8.5 1.73 2.05 0.84 0.073 PRESENT 850 INVENTION EXAMPLE 23 31 43 3.534 1.78 2.05 0.87 0.064 PRESENT 750 INVENTION EXAMPLE 24 32 57 1.8 1121.87 2.05 0.91 0.017 PRESENT 650 INVENTION EXAMPLE 25 33 56 2.1 110 1.882.05 0.92 0.013 PRESENT 550 INVENTION EXAMPLE 26 34 55 2.3 74 1.87 2.050.91 0.087 PRESENT 450 INVENTION EXAMPLE 27 35 40 3.9 2.1 1.76 2.05 0.860.139 PRESENT 300 INVENTION EXAMPLE 28 36 37 4.5 0.6 1.74 2.05 0.850.210 COMPARATIVE 250 EXAMPLE 8 37 16 13 0.8 1.60 2.05 0.78 0.086COMPARATIVE 950 EXAMPLE 9 38 27 11 2.2 1.65 2.05 0.80 0.079 PRESENT 920INVENTION EXAMPLE 29 39 32 9.4 8.2 1.73 2.05 0.84 0.079 PRESENT 850INVENTION EXAMPLE 30 40 45 3.1 34 1.81 2.05 0.88 0.065 PRESENT 750INVENTION EXAMPLE 31 41 58 1.4 158 1.87 2.05 0.91 0.013 PRESENT 650INVENTION EXAMPLE 32 42 57 1.9 189 1.89 2.05 0.92 0.009 PRESENT 550INVENTION EXAMPLE 33 43 56 2.1 48 1.88 2.05 0.92 0.091 PRESENT 450INVENTION EXAMPLE 34 44 43 3.8 2.7 1.77 2.05 0.86 0.136 PRESENT 300INVENTION EXAMPLE 35 45 41 5.1 1.4 1.76 2.05 0.86 0.192 COMPARATIVE 250EXAMPLE 10

TABLE 4 MANUFACTURE SEEDING BASE SEEDING SEEDING MATERIAL SECOND LAYERTEMPERATURE ACCUMULATION ACCUMULATION THICK- THICK- INCREASING DEGREE OFDEGREE OF NESS NESS BONDING RATE MEASURED {200} PLANES {222} PLANES No.No. mm ELEMENT μm METHOD ° C./sec TEMPERATURE IN αFe IN αFe 46 10 0.5 Ti10 SPUTTERING 50 1010 14 13 47 11 0.5 Ti 10 SPUTTERING 50 1010 25 11 4812 0.5 Ti 10 SPUTTERING 50 1010 30 9.3 49 13 0.5 Ti 10 SPUTTERING 501010 36 7.3 50 14 0.5 Ti 10 SPUTTERING 50 1010 38 6.7 51 15 0.5 Ti 10SPUTTERING 50 1010 38 6.4 52 16 0.5 Ti 10 SPUTTERING 50 1010 27 9.5 5317 0.5 Ti 10 SPUTTERING 50 1010 26 10 54 10 0.5 Ge 12 SPUTTERING 1001010 13 14 55 11 0.5 Ge 12 SPUTTERING 100 1010 26 11 56 12 0.5 Ge 12SPUTTERING 100 1010 30 9.1 57 13 0.5 Ge 12 SPUTTERING 100 1010 34 8.1 5814 0.5 Ge 12 SPUTTERING 100 1010 37 6.9 59 15 0.5 Ge 12 SPUTTERING 1001010 37 6.7 60 16 0.5 Ge 12 SPUTTERING 100 1010 26 10 61 17 0.5 Ge 12SPUTTERING 100 1010 25 12 62 10 0.5 Sb 15 SPUTTERING 1 1010 12 15 63 110.5 Sb 15 SPUTTERING 1 1010 26 10 64 12 0.5 Sb 15 SPUTTERING 1 1010 309.1 65 13 0.5 Sb 15 SPUTTERING 1 1010 35 8 66 14 0.5 Sb 15 SPUTTERING 11010 37 7.2 67 15 0.5 Sb 15 SPUTTERING 1 1010 37 7.4 68 16 0.5 Sb 15SPUTTERING 1 1010 26 10 69 17 0.5 Sb 15 SPUTTERING 1 1010 25 11 70 100.5 V 18 SPUTTERING 300 1010 13 13 71 11 0.5 V 18 SPUTTERING 300 1010 2610 72 12 0.5 V 18 SPUTTERING 300 1010 31 8.5 73 13 0.5 V 18 SPUTTERING300 1010 36 7.7 74 14 0.5 V 18 SPUTTERING 300 1010 38 6.3 75 15 0.5 V 18SPUTTERING 300 1010 37 6.7 76 16 0.5 V 18 SPUTTERING 300 1010 27 10 7717 0.5 V 18 SPUTTERING 300 1010 26 11 78 10 0.5 W 10 SPUTTERING 50 101013 14 79 11 0.5 W 10 SPUTTERING 50 1010 26 11 80 12 0.5 W 10 SPUTTERING50 1010 31 9.1 81 13 0.5 W 10 SPUTTERING 50 1010 35 7.9 82 14 0.5 W 10SPUTTERING 50 1010 37 6.4 83 15 0.5 W 10 SPUTTERING 50 1010 38 6.4 84 160.5 W 10 SPUTTERING 50 1010 26 10 85 17 0.5 W 10 SPUTTERING 50 1010 2511 MANUFACTURE SAVING AND ACHIEVEMENT OF HIGH ACCUMULATION ACHIEVEMENTACHIEVEMENT OF HIGH OF HIGH ACCUMULATION ACCUMULATION GROWTHACCUMULATION ACCUMULATION ½t ½t HOLDING HOLDING DEGREE OF DEGREE OFCOOLING ACCUMULATION ACCUMULATION TEMPERATURE TIME {200} PLANES {222}PLANES RATE DEGREE OF DEGREE OF No. ° C. sec IN αFe IN αFe ° C./sec{200} PLANES {222} PLANES 46 1100 10 15 14 50 15 14 47 1100 10 32 8.6 5032 8.6 48 1100 10 52 1.9 50 52 1.9 49 1100 10 67 0.7 50 67 0.7 50 110010 71 0.3 50 71 0.3 51 1100 10 68 0.8 50 68 0.8 52 1100 10 44 3.8 50 443.8 53 1100 10 40 4.9 50 40 4.9 54 1250 30 16 13 150 16 13 55 1250 30 338.3 150 33 8.3 56 1250 30 51 1.9 150 51 1.9 57 1250 30 65 0.8 150 65 0.858 1250 30 70 0.3 150 70 0.3 59 1250 30 67 0.7 150 67 0.7 60 1250 30 433.9 150 43 3.9 61 1250 30 41 4.5 150 41 4.5 62 1050 100 16 12 20 16 1263 1050 100 31 9.2 20 31 9.2 64 1050 100 50 2.4 20 50 2.4 65 1050 100 660.9 20 66 0.9 66 1050 100 69 0.4 20 69 0.4 67 1050 100 64 1.1 20 64 1.168 1050 100 42 4.1 20 42 4.1 69 1050 100 39 5.2 20 39 5.2 70 1150 200 1414 5 14 14 71 1150 200 33 8.4 5 33 8.4 72 1150 200 53 1.5 5 53 1.5 731150 200 66 0.8 5 66 0.8 74 1150 200 70 0.4 5 70 0.4 75 1150 200 67 0.85 67 0.8 76 1150 200 44 3.4 5 44 3.4 77 1150 200 41 4.8 5 41 4.8 78 1300500 17 12 250 17 12 79 1300 500 34 8.7 250 34 8.7 80 1300 500 54 1.4 25054 1.4 81 1300 500 65 0.9 250 65 0.9 82 1300 500 68 0.6 250 68 0.6 831300 500 65 1 250 65 1 84 1300 500 43 3..5 250 43 3..5 85 1300 500 404.8 250 40 4.8 PRODUCT TEXTURE EVALUATION ACCUMULATION ACCUMULATIONDEGREE OF DEGREE OF MAGNETIC FLUX {200} PLANES {222} PLANES DENSITYEVALUATION α-REGION No. IN αFe IN αFe Z B50 T Bs T B50/Bs ΔB T NOTETEMPERATURE 46 15 14 0.5 1.59 2.02 0.79 0.090 COMPARATIVE 1050 EXAMPLE11 47 32 8.6 2.5 1.73 2.02 0.86 0.080 PRESENT 950 INVENTION EXAMPLE 3648 52 1.9 12   1.78 2.02 0.88 0.080 PRESENT 850 INVENTION EXAMPLE 37 4967 0.7 75   1.89 2.02 0.94 0.030 PRESENT 750 INVENTION EXAMPLE 38 50 710.3 143    1.93 2.02 0.96 0.015 PRESENT 600 INVENTION EXAMPLE 39 51 680.8 116    1.92 2.02 0.95 0.019 PRESENT 450 INVENTION EXAMPLE 40 52 443.8 2.9 1.76 2.02 0.87 0.115 PRESENT 300 INVENTION EXAMPLE 41 53 40 4.90.9 1.75 2.02 0.87 0.200 COMPARATIVE 250 EXAMPLE 12 54 16 13 0.7 1.582.02 0.78 0.091 COMPARATIVE 1050 EXAMPLE 13 55 33 8.3 2.9 1.72 2.02 0.850.083 PRESENT 950 INVENTION EXAMPLE 42 56 51 1.9 18   1.79 2.02 0.890.070 PRESENT 850 INVENTION EXAMPLE 43 57 65 0.8 83   1.87 2.02 0.930.070 PRESENT 750 INVENTION EXAMPLE 44 58 70 0.3 183    1.93 2.02 0.960.045 PRESENT 600 INVENTION EXAMPLE 45 59 67 0.7 127    1.93 2.02 0.960.031 PRESENT 450 INVENTION EXAMPLE 46 60 43 3.9 4.7 1.77 2.02 0.880.138 PRESENT 300 INVENTION EXAMPLE 47 61 41 4.5 1.2 1.75 2.02 0.870.190 COMPARATIVE 250 EXAMPLE 14 62 16 12 1.1 1.59 2.02 0.79 0.090COMPARATIVE 1050 EXAMPLE 15 63 31 9.2 2.4 1.73 2.02 0.86 0.080 PRESENT950 INVENTION EXAMPLE 48 64 50 2.4 15   1.78 2.02 0.88 0.080 PRESENT 850INVENTION EXAMPLE 49 65 66 0.9 77   1.87 2.02 0.93 0.076 PRESENT 750INVENTION EXAMPLE 50 66 69 0.4 125    1.92 2.02 0.95 0.050 PRESENT 600INVENTION EXAMPLE 51 67 64 1.1 108    1.92 2.02 0.95 0.042 PRESENT 450INVENTION EXAMPLE 52 68 42 4.1 2.6 1.77 2.02 0.88 0.138 PRESENT 300INVENTION EXAMPLE 53 69 39 5.2 1.4 1.76 2.02 0.87 0.220 COMPARATIVE 250EXAMPLE 16 70 14 14 0.4 1.58 2.02 0.78 0.230 COMPARATIVE 1050 EXAMPLE 1771 33 8.4 2.9 1.72 2.02 0.85 0.135 PRESENT 950 INVENTION EXAMPLE 54 7253 1.5 36   1.77 2.02 0.88 0.094 PRESENT 850 INVENTION EXAMPLE 55 73 660.8 98   1.87 2.02 0.93 0.075 PRESENT 750 INVENTION EXAMPLE 56 74 70 0.4178    1.94 2.02 0.96 0.061 PRESENT 600 INVENTION EXAMPLE 57 75 67 0.847   1.94 2.02 0.96 0.042 PRESENT 450 INVENTION EXAMPLE 58 76 44 3.410.4  1.76 2.02 0.87 0.137 PRESENT 300 INVENTION EXAMPLE 59 77 41 4.81.2 1.75 2.02 0.87 0.230 COMPARATIVE 250 EXAMPLE 18 78 17 12 0.9 1.592.02 0.79 0.210 COMPARATIVE 1050 EXAMPLE 19 79 34 8.7 4.7 1.73 2.02 0.860.143 PRESENT 950 INVENTION EXAMPLE 60 80 54 1.4 45   1.78 2.02 0.880.090 PRESENT 850 INVENTION EXAMPLE 61 81 65 0.9 118    1.87 2.02 0.930.064 PRESENT 750 INVENTION EXAMPLE 62 82 68 0.6 159    1.92 2.02 0.950.020 PRESENT 600 INVENTION EXAMPLE 63 83 65 1 69   1.92 2.02 0.95 0.031PRESENT 450 INVENTION EXAMPLE 64 84 43 3..5 3.7 1.76 2.02 0.87 0.120PRESENT 300 INVENTION EXAMPLE 65 85 40 4.8 1.7 1.75 2.02 0.87 0.230COMPARATIVE 250 EXAMPLE 20

In each of present invention examples, it was possible to confirm that Zis not less than 2.0 nor more than 200, the magnetic flux densitydifference ΔB becomes a small value as compared to comparative examples,and a high magnetic flux density can be obtained thoroughly in anin-plane circumferential direction. Further, in these Fe-based metalsheets, it was possible to confirm that an excellent magnetic propertyin which the value of B50/Bs is 0.80 or more is obtained.

Further, in the present invention examples, as shown in Table 2 to Table4, it was possible to confirm that the (200) plane in the α-Fe phase islikely to be highly accumulated at each of the stages of the heattreatment.

Further, an L cross section of each of the present invention exampleswas observed, and thereby it was confirmed that the α single phaseregion made of the α single phase based component exists in at least apartial region including the surfaces and a ratio of the α single phaseregion to the L cross section is 1% or more.

When the Z value was not less than 2 nor more than 200 as defined in thepresent invention as above, it was possible to confirm that a highmagnetic flux density is obtained thoroughly in the in-planecircumferential direction. Further, in order to obtain the Fe-basedmetal sheet as above, the α-region rolling was performed at atemperature of higher than 300° C. and lower than the A3 point betweenthe hot rolling and the cold rolling, thereby making it possible toobtain an intended product.

In contrast to this, when the base metal sheets obtained by performingthe rolling under the conditions not satisfying the requirements of thepresent invention were used, it was not possible to obtain a highmagnetic flux density such as that in the present invention examples inthe in-plane circumferential direction thoroughly.

Example 2

In this example, base metal sheets of No. 18 to No. 35 each made of acomponent C, D, or E shown in Table 1 were manufactured under variousrolling conditions, to then have various different metals appliedthereto as a second layer, and then Fe-based metal sheets werefabricated, of which the previously described Z value (=(A+0.97B)/0.98C)and the magnetic flux density difference ΔB were examined. Further, therelationship between various manufacturing conditions and anaccumulation degree of {200} planes was also examined. Further, effectsobtained by changing a starting temperature in an α-region rollingprocess were also examined in detail.

First, ingots each having the component C, D, or E shown in Table 1 anda balance being composed of Fe and inevitable impurities were melted byvacuum melting. Then, these were used as rolling materials to be workedinto cold-rolled sheets (the base metal sheets) each having apredetermined thickness under conditions of hot rolling, α-regionrolling, and cold rolling shown in Table 5 below.

TABLE 5 α-REGION HOT ROLLING ROLLING START FINISH START FINISH BASETEMPER- THICK- TEMPER- THICK- REDUC- TEMPER- THICK- TEMPER- MATERIAL A3ATURE NESS ATURE NESS TION ATURE NESS ATURE No. COMPONENT POINT ° C. mm° C. mm RATIO ° C. mm ° C. 18 C 915 1050 200 930 60 −1.20 700 60 610 19C 915 1050 200 930 30 −1.90 700 30 610 20 C 915 1050 200 930 20 −2.30700 20 610 21 C 915 1050 200 930 10 −3.00 700 10 610 22 C 915 1050 200930 8 −3.22 700 8 610 23 C 915 1050 200 930 4 −3.91 700 4 610 24 D 8701050 300 930 15 −3.00 650 15 570 25 D 870 1050 150 930 15 −2.30 650 15570 26 D 870 1050 75 930 15 −1.61 650 15 570 27 D 870 1050 50 930 15−1.20 650 15 570 28 D 870 1050 20 930 15 −0.29 650 15 570 29 E 942 1200240 1050 50 −1.67 750 30 670 30 E 942 1200 240 1050 50 −1.57 750 30 67031 E 942 1200 240 1050 50 −1.57 750 30 670 32 E 942 1200 240 1050 50−1.57 750 30 670 33 E 942 1200 240 1050 50 −1.57 750 30 670 34 E 9421200 240 1050 50 −1.57 750 30 670 35 E 942 1200 240 1050 50 −1.57 750 30670 α-REGION ROLLING COLD ROLLING FINISH START FINISH TOTAL BASE THICK-REDUC- THICK- THICK- REDUC- REDUC- α REGION + MATERIAL NESS TION NESSNESS TION TION COLD No. mm RATIO mm mm RATIO RATIO ROLLING 18 2 −3.40 20.35 −1.74 −6.35 −5.14 19 2 −2.71 2 0.35 −1.74 −6.35 −4.45 20 2 −2.30 20.35 −1.74 −6.35 −4.05 21 2 −1.61 2 0.35 −1.74 −6.35 −3.35 22 2 −1.39 20.35 −1.74 −6.35 −3.13 23 2 −0.69 2 0.35 −1.74 −6.35 −2.44 24 3.5 −1.463.5 0.5 −1.95 −6.40 −3.40 25 3.5 −1.46 3.5 0.6 −1.95 −5.70 −3.40 26 3.5−1.46 3.5 0.5 −1.95 −5.01 −3.40 21 3.5 −1.46 3.5 0.5 −1.95 −4.61 −3.4028 3.5 −1.46 3.5 0.5 −1.95 −3.69 −3.40 29 6 −1.61 6 3 −0.69 −3.87 −2.3030 6 −1.61 6 2 −1.10 −4.28 −2.71 31 6 −1.61 6 1 −1.79 −4.97 −3.40 32 6−1.61 6 0.2 −3.40 −6.58 −5.01 33 6 −1.61 6 0.1 −4.09 −7.27 −5.70 34 6−1.61 6 0.05 −4.79 −7.97 −6.40 35 6 −1.61 6 0.01 −6.40 −9.57 −8.01

In the case of the component C, first, the ingots each having athickness of 200 mm heated to 1050° C. were each subjected to hotrolling at a reduction ratio of −1.20 to - 3.91 in terms of true strain,and hot-rolled sheets each having a thickness of 4 mm to 60 mm wereobtained. Next, α-region rolling was started at 700° C., and thesehot-rolled sheets were each subjected to the α-region rolling at areduction ratio of −0.69 to −3.40 in terms of true strain to a thicknessof 2 mm. Then, these rolled sheets were pickled, and then the base metalsheets were obtained by cold rolling. At this time, the reduction ratiowas −1.74 in terms of true strain, and as a result, the thickness ofeach of the obtained base metal sheets was 0.35 mm.

In the case of the component D, first, the ingots each having athickness of 20 mm to 300 mm heated to 1050° C. were each subjected tohot rolling at a reduction ratio of −0.29 to −3.00 in terms of truestrain, and hot-rolled sheets each having a thickness of 15 mm wereobtained. Next, α-region rolling was started at 650° C., and thesehot-rolled sheets were each subjected to the α-region rolling at areduction ratio of −1.46 in terms of true strain to a thickness of 3.5mm. Then, these rolled sheets were pickled, and then the base metalsheets were obtained by cold rolling. At this time, the reduction ratiowas −1.95 in terms of true strain, and as a result, the thickness ofeach of the obtained base metal sheets was 0.50 mm.

In the case of the component E, first, the ingots each having athickness of 240 mm heated to 1200° C. were each subjected to hotrolling at a reduction ratio of −1.57 in terms of true strain, andhot-rolled sheets each having a thickness of 50 mm were obtained. Next,α-region rolling was started at 750° C., and these hot-rolled sheetswere each subjected to the α-region rolling at a reduction ratio of−1.61 in terms of true strain to a thickness of 6.0 mm. Then, theserolled sheets were pickled, and then the base metal sheets were obtainedby cold rolling. At this time, each of the reduction ratios was −0.69 to−6.40 in terms of true strain, and as a result, the thickness of each ofthe obtained base metal sheets was 0.01 mm to 3.0 mm.

With respect to the base metal sheets obtained by the above procedure, atexture of a surface layer portion of each of the base materials wasmeasured by X-ray diffraction to obtain an accumulation degree of {200}planes and an accumulation degree of {222} planes by the previouslydescribed method. Further, thinning was performed so that a structurecould be observed from a direction perpendicular to an L cross-section,and a region up to ¼t from the surface was observed. The main phase ofeach of the obtained base metal sheets at room temperature was an α-Fephase. Further, as a result of measurement, the A3 point at which theα-γtransformation occurred was 915° C. in the component C, 870° C. inthe component D, and 942° C. in the component E.

Next, both surfaces of each of the base metal sheets of No. 18 to No. 35shown in Table 5 were coated with each of various different metalelements as the second layer by a vapor deposition method, a sputteringmethod, an electroplating method, or a hot dipping method. As shown inTable 6 and Table 7 below, as the different metal element, any one ofAl, Si, Ga, Sn, V, W, Mo, and Zn was selected. The thickness of each ofthe coatings was as shown in Table 6 and Table 7.

Next, an experiment was performed in which a heat treatment wasperformed on the base metal sheets to each of which the second layerswere bonded under various conditions. As a method of the experiment, theexperiment was performed by the same method described in Example 1.Further, the observation of a texture in this period was also performedby the same method described in Example 1.

Further, magnetometry was performed in the same manner as that inExample 1 in order to evaluate obtained products, and further the Zvalue was calculated by X-ray diffraction.

Table 6 and Table 7 below show the accumulation degrees of the {200}planes and the accumulation degrees of the {222} planes measured in therespective processes during the manufacture and after the manufacture,the Z values of the obtained Fe-based metal sheets, and evaluationresults of the magnetometry.

TABLE 6 MANUFACTURE SEEDING BASE SEEDING SEEDING MATERIAL SECOND LAYERTEMPERATURE ACCUMULATION ACCUMULATION THICK- THICK- INCREASING DEGREE OFDEGREE OF NESS NESS BONDING RATE MEASURED {200} PLANES {222} PLANES No.No. mm ELEMENT μm METHOD ° C./sec TEMPERATURE IN αFe IN αFe 86 18 0.35Al 7 VAPOR 20 915 34 7.8 DEPOSITION 87 19 0.35 Al 7 VAPOR 20 915 34 7.9DEPOSITION 88 20 0.35 Al 7 VAPOR 20 915 33 8.3 DEPOSITION 89 21 0.35 Al7 VAPOR 20 915 30 9.3 DEPOSITION 90 22 0.35 Al 7 VAPOR 20 915 28 10DEPOSITION 91 23 0.35 Al 7 VAPOR 20 915 26 10 DEPOSITION 92 18 0.35 Si 8SPUTTERING 10 915 35 7.1 93 19 0.35 Si 8 SPUTTERING 10 915 34 7.3 94 200.35 Si 8 SPUTTERING 10 915 32 7.8 95 21 0.35 Si 8 SPUTTERING 10 915 279.7 96 22 0.35 Si 8 SPUTTERING 10 915 26 10 97 23 0.35 Si 8 SPUTTERING10 915 25 11 98 18 0.35 Ga 6 VAPOR 0.5 915 32 8.5 DEPOSITION 99 19 0.35Ga 6 VAPOR 0.5 915 32 8.6 DEPOSITION 100 20 0.35 Ga 6 VAPOR 0.5 915 318.9 DEPOSITION 101 21 0.35 Ga 6 VAPOR 0.5 915 28 9.8 DEPOSITION 102 220.35 Ga 6 VAPOR 0.5 915 26 10 DEPOSITION 103 23 0.35 Ga 6 VAPOR 0.5 91525 11 DEPOSITION 104 18 0.35 Sn 10 ELECTROLYTIC 5 915 36 6.5 PLATING 10519 0.35 Sn 10 ELECTROLYTIC 5 915 35 6.7 PLATING 106 20 0.35 Sn 10ELECTROLYTIC 5 915 36 7.2 PLATING 107 21 0.35 Sn 10 ELECTROLYTIC 5 91531 8.7 PLATING 108 22 0.35 Sn 10 ELECTROLYTIC 5 915 27 9.3 PLATING 10923 0.35 Sn 10 ELECTROLYTIC 5 915 25 11 PLATING 110 18 0.35 V 11SPUTTERING 10 915 34 7.9 111 19 0.35 V 11 SPUTTERING 10 915 33 8.2 11220 0.35 V 11 SPUTTERING 10 915 31 8.6 113 21 0.35 V 11 SPUTTERING 10 91528 9.7 114 22 0.35 V 11 SPUTTERING 10 915 27 10 115 23 0.35 V 11SPUTTERING 10 915 25 10 116 18 0.35 W 6 SPUTTERING 0.5 915 34 7.6 117 190.35 W 6 SPUTTERING 0.5 915 33 8.2 118 20 0.35 W 6 SPUTTERING 0.5 915 319.2 119 21 0.35 W 6 SPUTTERING 0.5 915 28 10 120 22 0.35 W 6 SPUTTERING0.5 915 27 10 121 23 0.35 W 6 SPUTTERING 0.5 915 25 11 MANUFACTURESAVING AND ACHIEVEMENT OF HIGH ACCUMULATION ACHIEVEMENT ACHIEVEMENT OFHIGH OF HIGH ACCUMULATION ACCUMULATION GROWTH ACCUMULATION ACCUMULATION½t ½t HOLDING HOLDING DEGREE OF DEGREE OF COOLING ACCUMULATIONACCUMULATION TEMPERATURE TIME {200} PLANES {222} PLANES RATE DEGREE OFDEGREE OF No. ° C. sec IN αFe IN αFe ° C./sec {200} PLANES {222} PLANES86 1000 40 63 0.8 100 63 0.8 87 1000 40 62 0.8 100 62 0.8 88 1000 40 610.9 100 61 0.9 89 1000 40 50 3.9 100 50 3.9 90 1000 40 42 5.7 100 42 5.791 1000 40 32 8.5 100 32 8.5 92 1050 25 62 0.9 20 62 0.9 93 1050 25 610.9 20 61 0.9 94 1050 25 60 1.2 20 60 1.2 95 1050 25 45 3.5 20 45 3.5 961050 25 42 5.3 20 42 5.3 97 1050 25 31 9.1 20 31 9.1 98 950 120 60 1.150 60 1.1 99 950 120 60 1 50 60 1 100 950 120 59 1.2 50 59 1.2 101 950120 43 4.5 50 43 4.5 102 950 120 41 6.2 50 41 6.2 103 950 120 30 9.7 5030 9.7 104 1000 10 64 0.7 200 64 0.7 105 1000 10 64 0.7 200 64 0.7 1061000 10 63 0.8 200 63 0.8 107 1000 10 50 2.8 200 50 2.8 108 1000 10 434.7 200 43 4.7 109 1000 10 33 7.9 200 33 7.9 110 1200 15 61 0.9 250 610.9 111 1200 15 61 0.9 250 61 0.9 112 1200 15 60 1.2 250 60 1.2 113 120015 45 4.3 250 45 4.3 114 1200 15 39 6.6 250 39 6.6 115 1200 15 30 8.2250 30 8.2 116 1300 30 60 1.1 80 60 1.1 117 1300 30 59 1.3 80 59 1.3 1181300 30 58 1.6 80 58 1.6 119 1300 30 46 3.5 80 46 3.5 120 1300 30 38 6.980 38 8.9 121 1300 30 31 9.1 80 31 9.1 PRODUCT TEXTURE EVALUATIONACCUMULATION ACCUMULATION DEGREE OF DEGREE OF MAGNETIC FLUX {200} PLANES{222} PLANES DENSITY EVALUATION α-REGION No. IN αFe IN αFe Z B50 T Bs TB50/Bs ΔB T NOTE TEMPERATURE 86 63 0.8 135 1.87 2.04 0.92 0.038 PRESENT700 INVENTION EXAMPLE 66 87 62 0.8 120 1.86 2.04 0.91 0.048 PRESENT 700INVENTION EXAMPLE 67 88 61 0.9 52 1.86 2.04 0.91 0.053 PRESENT 700INVENTION EXAMPLE 68 89 47 3.9 24 1.82 2.04 0.89 0.068 PRESENT 700INVENTION EXAMPLE 89 90 40 5.7 8.6 1.76 2.04 0.86 0.076 PRESENT 700INVENTION EXAMPLE 70 91 32 8.5 2.5 1.72 2.04 0.84 0.091 PRESENT 700INVENTION EXAMPLE 71 92 62 0.9 157 1.86 2.04 0.91 0.035 PRESENT 700INVENTION EXAMPLE 72 93 61 0.9 132 1.86 2.04 0.91 0.046 PRESENT 700INVENTION EXAMPLE 73 94 60 1.2 62 1.85 2.04 0.91 0.057 PRESENT 700INVENTION EXAMPLE 74 95 45 3.5 28 1.78 2.04 0.87 0.066 PRESENT 700INVENTION EXAMPLE 75 96 42 5.3 9.4 1.76 2.04 0.86 0.084 PRESENT 700INVENTION EXAMPLE 76 97 31 9.1 3.8 1.73 2.04 0.85 0.091 PRESENT 700INVENTION EXAMPLE 77 98 60 1.1 167 1.86 2.04 0.91 0.031 PRESENT 700INVENTION EXAMPLE 78 99 60 1 121 1.86 2.04 0.91 0.047 PRESENT 700INVENTION EXAMPLE 79 100 59 1.2 71 1.85 2.04 0.91 0.054 PRESENT 700INVENTION EXAMPLE 80 101 43 4.5 31 1.79 2.04 0.88 0.068 PRESENT 700INVENTION EXAMPLE 81 102 41 6.2 10 1.76 2.04 0.86 0.079 PRESENT 700INVENTION EXAMPLE 82 103 30 9.7 2.6 1.72 2.04 0.84 0.087 PRESENT 700INVENTION EXAMPLE 83 104 64 0.7 184 1.88 2.04 0.92 0.027 PRESENT 700INVENTION EXAMPLE 84 105 64 0.7 137 1.87 2.04 0.92 0.044 PRESENT 700INVENTION EXAMPLE 85 106 63 0.8 68 1.88 2.04 0.92 0.057 PRESENT 700INVENTION EXAMPLE 86 107 50 2.8 32 1.81 2.04 0.89 0.071 PRESENT 700INVENTION EXAMPLE 87 108 43 4.7 9.4 1.75 2.04 0.86 0.082 PRESENT 700INVENTION EXAMPLE 88 109 33 7.9 3.1 1.71 2.04 0.84 0.094 PRESENT 700INVENTION EXAMPLE 89 110 61 0.9 154 1.87 2.04 0.92 0.022 PRESENT 700INVENTION EXAMPLE 90 111 61 0.9 118 1.87 2.04 0.92 0.039 PRESENT 700INVENTION EXAMPLE 91 112 60 1.2 66 1.86 2.04 0.91 0.053 PRESENT 700INVENTION EXAMPLE 92 113 45 4.3 24 1.81 2.04 0.89 0.067 PRESENT 700INVENTION EXAMPLE 93 114 39 6.6 8.9 1.76 2.04 0.86 0.075 PRESENT 700INVENTION EXAMPLE 94 115 30 8.2 4.2 1.72 2.04 0.84 0.088 PRESENT 700INVENTION EXAMPLE 95 116 60 1.1 186 1.86 2.04 0.91 0.019 PRESENT 700INVENTION EXAMPLE 96 117 59 1.3 136 1.85 2.04 0.91 0.032 PRESENT 700INVENTION EXAMPLE 97 118 58 1.6 74 1.85 2.04 0.91 0.050 PRESENT 700INVENTION EXAMPLE 98 119 46 3.5 28 1.79 2.04 0.88 0.062 PRESENT 700INVENTION EXAMPLE 99 120 38 6.9 12 1.76 2.04 0.86 0.072 PRESENT 700INVENTION EXAMPLE 100 121 31 9.1 3.9 1.71 2.04 0.84 0.093 PRESENT 700INVENTION EXAMPLE 101

TABLE 7 MANUFACTURE SEEDING BASE SEEDING SEEDING MATERIAL SECOND LAYERTEMPERATURE ACCUMULATION ACCUMULATION THICK- THICK- INCREASING DEGREE OFDEGREE OF NESS NESS BONDING RATE MEASURED {200} PLANES {222} PLANES No.No. mm ELEMENT μm METHOD ° C./sec TEMPERATURE IN αFe IN αFe 122 24 0.5Al 10 VAPOR 10 870 31 7.7 DEPOSITION 123 25 0.5 Al 10 VAPOR 10 870 317.9 DEPOSITION 124 26 0.5 Al 10 VAPOR 10 870 30 9.3 DEPOSITION 125 270.5 Al 10 VAPOR 10 870 27 9.8 DEPOSITION 126 28 0.5 Al 10 VAPOR 10 87025 10 DEPOSITION 127 24 0.5 Si 12 VAPOR 20 870 31 8.1 DEPOSITION 128 250.5 Si 12 VAPOR 20 870 31 8.2 DEPOSITION 129 26 0.5 Si 12 VAPOR 20 87030 9.3 DEPOSITION 130 27 0.5 Si 12 VAPOR 20 870 27 10 DEPOSITION 131 280.5 Si 12 VAPOR 20 870 26 11 DEPOSITION 132 24 0.5 Mo 8 SPUTTERING 1 87033 6.8 133 25 0.5 Mo 8 SPUTTERING 1 870 32 7.3 134 26 0.5 Mo 8SPUTTERING 1 870 30 8.8 135 27 0.5 Mo 8 SPUTTERING 1 870 27 9.3 136 280.5 Mo 8 SPUTTERING 1 870 25 10 137 29 3 Al 120 HOT DIPPING 2 942 13 13138 30 2 Al 80 HOT DIPPING 2 942 25 10 139 31 1 Al 40 HOT DIPPING 2 94231 8.3 140 32 0.2 Al 8 VAPOR 2 942 32 7.5 DEPOSITION 141 33 0.1 Al 4VAPOR 2 942 33 6.7 DEPOSITION 142 34 0.05 Al 2 VAPOR 2 942 33 6.5DEPOSITION 143 35 0.01 Al 0.4 VAPOR 2 942 32 6.4 DEPOSITION 144 29 3 Sn60 HOT DIPPING 5 942 12 12 145 30 2 Sn 40 HOT DIPPING 5 942 25 10 146 311 Sn 20 HOT DIPPING 5 942 32 8.1 147 32 0.2 Sn 4 ELECTROLYTIC 5 942 337.1 PLATING 148 33 0.1 Sn 2 ELECTROLYTIC 5 942 34 6.3 PLATING 149 340.05 Sn 1 ELECTROLYTIC 5 942 35 6.1 PLATING 150 35 0.01 Sn 0.2ELECTROLYTIC 5 942 34 6.6 PLATING 151 29 3 Zn 60 HOT DIPPING 1 942 14 13152 30 2 Zn 40 HOT DIPPING 1 942 25 11 153 31 1 Zn 20 HOT DIPPING 1 94230 8.8 154 32 0.2 Zn 4 ELECTROLYTIC 1 942 31 7.8 PLATING 155 33 0.1 Zn 2ELECTROLYTIC 1 942 32 6.5 PLATING 156 34 0.05 Zn 1 ELECTROLYTIC 1 942 326.3 PLATING 157 35 0.01 Zn 0.2 ELECTROLYTIC 1 942 32 6.7 PLATINGMANUFACTURE SAVING AND ACHIEVEMENT OF HIGH ACCUMULATION ACHIEVEMENTACHIEVEMENT OF HIGH OF HIGH ACCUMULATION ACCUMULATION GROWTHACCUMULATION ACCUMULATION ½t ½t HOLDING HOLDING DEGREE OF DEGREE OFCOOLING ACCUMULATION ACCUMULATION TEMPERATURE TIME {200} PLANES {222}PLANES RATE DEGREE OF DEGREE OF No. ° C. sec IN αFe IN αFe ° C./sec{200} PLANES {222} PLANES 122 930 20 56 1.6 80 56 1.6 123 930 20 55 1.880 55 1.8 124 930 20 52 2.5 80 52 2.5 125 930 20 40 5.9 80 40 5.9 126930 20 32 9.3 80 32 9.3 127 980 60 54 1.7 20 54 1.7 128 980 60 53 1.9 2053 1.9 129 980 60 51 2.8 20 51 2.8 130 980 60 39 7.4 20 39 7.4 131 98060 33 9.5 20 33 9.5 132 1000 15 56 1.7 50 56 1.7 133 1000 15 56 1.7 5056 1.7 134 1000 15 53 2.1 50 53 2.1 135 1000 15 41 6.3 50 41 6.3 1361000 15 31 9.3 50 31 9.3 137 1050 25 15 13 100 15 13 138 1050 25 32 9.5100 32 9.5 139 1050 25 50 2.8 100 50 2.8 140 1050 25 54 2.1 100 54 2.1141 1050 25 55 1.8 100 55 1.8 142 1050 25 56 1.7 100 56 1.7 143 1050 2555 1.8 100 55 1.8 144 1100 60 14 14 200 14 14 145 1100 60 32 9.4 200 329.4 146 1100 60 51 2.5 200 51 2.5 147 1100 60 56 1.8 200 56 1.8 148 110060 57 1.3 200 57 1.3 149 1100 60 57 1.1 200 57 1.1 150 1100 60 56 1.4200 56 1.4 151 980 200 16 12 50 16 12 152 980 200 30 9.8 50 30 9.8 153980 200 50 3.1 50 50 3.1 154 980 200 52 2.5 50 52 2.5 155 980 200 54 2.150 54 2.1 156 980 200 55 1.9 50 55 1.9 157 980 200 54 2.1 50 54 2.1PRODUCT TEXTURE EVALUATION ACCUMULATION ACCUMULATION DEGREE OF DEGREE OFMAGNETIC FLUX {200} PLANES {222} PLANES DENSITY EVALUATION α-REGION No.IN αFe IN αFe Z B50 T Bs T B50/Bs ΔB T NOTE TEMPERATURE 122 56 1.6 981.85 1.98 0.93 0.024 PRESENT 650 INVENTION EXAMPLE 102 123 55 1.8 781.85 1.98 0.93 0.028 PRESENT 650 INVENTION EXAMPLE 103 124 52 2.5 571.83 1.98 0.92 0.041 PRESENT 650 INVENTION EXAMPLE 104 125 40 5.9 241.73 1.98 0.87 0.057 PRESENT 650 INVENTION EXAMPLE 105 126 32 9.3   3.81.69 1.98 0.85 0.087 PRESENT 650 INVENTION EXAMPLE 106 127 54 1.7 110 1.84 1.98 0.93 0.021 PRESENT 650 INVENTION EXAMPLE 107 128 53 1.9 761.84 1.98 0.93 0.025 PRESENT 650 INVENTION EXAMPLE 108 129 51 2.8 651.82 1.98 0.92 0.035 PRESENT 650 INVENTION EXAMPLE 109 130 39 7.4 291.76 1.98 0.89 0.053 PRESENT 650 INVENTION EXAMPLE 110 131 33 9.5   5.61.68 1.98 0.85 0.086 PRESENT 650 INVENTION EXAMPLE 111 132 56 1.7 105 1.86 1.98 0.94 0.023 PRESENT 650 INVENTION EXAMPLE 112 133 56 1.7 681.86 1.98 0.94 0.031 PRESENT 650 INVENTION EXAMPLE 113 134 53 2.1 591.84 1.98 0.93 0.045 PRESENT 650 INVENTION EXAMPLE 114 135 41 6.3 231.77 1.98 0.89 0.072 PRESENT 650 INVENTION EXAMPLE 115 136 31 9.3   4.21.68 1.98 0.85 0.092 PRESENT 650 INVENTION EXAMPLE 116 137 15 13   0.91.59 2.02 0.79 0.086 COMPARATIVE 750 EXAMPLE 21 138 32 9.5   2.5 1.732.02 0.86 0.062 PRESENT 750 INVENTION EXAMPLE 117 139 50 2.8 35 1.792.02 0.89 0.053 PRESENT 750 INVENTION EXAMPLE 118 140 54 2.1 65 1.832.02 0.91 0.041 PRESENT 750 INVENTION EXAMPLE 119 141 55 1.8 114  1.832.02 0.91 0.032 PRESENT 750 INVENTION EXAMPLE 120 142 56 1.7 126  1.832.02 0.91 0.018 PRESENT 750 INVENTION EXAMPLE 121 143 55 1.8 132  1.832.02 0.91 0.015 PRESENT 750 INVENTION EXAMPLE 122 144 14 14   0.4 1.602.02 0.79 0.092 COMPARATIVE 750 EXAMPLE 22 145 32 9.4   3.2 1.72 2.020.85 0.068 PRESENT 750 INVENTION EXAMPLE 123 146 51 2.5 29 1.76 2.020.87 0.052 PRESENT 750 INVENTION EXAMPLE 124 147 56 1.8 59 1.84 2.020.91 0.043 PRESENT 750 INVENTION EXAMPLE 125 148 57 1.3 94 1.84 2.020.91 0.029 PRESENT 750 INVENTION EXAMPLE 126 149 57 1.1 123  1.85 2.020.92 0.021 PRESENT 750 INVENTION EXAMPLE 127 150 56 1.4 135  1.84 2.020.91 0.018 PRESENT 750 INVENTION EXAMPLE 128 151 16 12   1.1 1.58 2.020.78 0.087 COMPARATIVE 750 EXAMPLE 23 152 30 9.8   4.5 1.71 2.02 0.850.058 PRESENT 750 INVENTION EXAMPLE 129 153 50 3.1 27 1.79 2.02 0.890.047 PRESENT 750 INVENTION EXAMPLE 130 154 52 2.5 49 1.83 2.02 0.910.039 PRESENT 750 INVENTION EXAMPLE 131 155 54 2.1 79 1.83 2.02 0.910.025 PRESENT 750 INVENTION EXAMPLE 132 156 55 1.9 132  1.83 2.02 0.910.018 PRESENT 750 INVENTION EXAMPLE 133 157 54 2.1 172  1.83 2.02 0.910.012 PRESENT 750 INVENTION EXAMPLE 134

In each of present invention examples, it was possible to confirm thatthe magnetic flux density difference ΔB becomes a small value ascompared to comparative examples, and a high magnetic flux density isobtained thoroughly in an in-plane circumferential direction. Further,in these Fe-based metal sheets, it was possible to confirm that anexcellent magnetic property in which the value of B50/Bs is 0.86 or moreis obtained.

Further, in the present invention examples, as shown in Table 5 to Table7, it was possible to confirm that the {200} plane in the α-Fe phase islikely to be highly accumulated at each of the stages of the heattreatment.

Further, an L cross section of each of the present invention exampleswas observed, and thereby it was confirmed that the α single phaseregion made of the α single phase based component exists in at least apartial region including the surfaces and a ratio of the α single phaseregion to the L cross section is 1% or more.

When the Z value was not less than 2 nor more than 200 as defined in thepresent invention as above, it was possible to confirm that a highmagnetic flux density is obtained thoroughly in the in-planecircumferential direction. Further, in order to obtain the Fe-basedmetal sheet as above, the α-region rolling was performed at atemperature of 300° C. or higher and lower than the A3 point between thehot rolling and the cold rolling, thereby making it possible to obtainan intended product.

In contrast to this, when the base metal sheets obtained by performingthe α-region rolling under the condition not satisfying the requirementsof the present invention were used, it was not possible to obtain a highmagnetic flux density such as that in the present invention examples inthe in-plane circumferential direction thoroughly.

Example 3

In this example, as base metal sheets, Fe-based metal sheets werefabricated in a manner that pure irons each containing C: 0.050 mass %,Si: 0.0001 mass %, and Al: 0.0002 mass %, and having a balance beingcomposed of Fe and inevitable impurities were subjected todecarburization to have Al applied thereto as a second layer, of whichthe previously described Z value (=(A+0.97B)/0.98C) and the magneticflux density difference ΔB were examined. Further, the relationshipbetween manufacturing conditions and an accumulation degree of {200}planes was also examined.

First, ingots were melted by vacuum melting, and then were subjected tohot rolling and cold rolling to be worked to a predetermined thickness,and the base metal sheets each composed of the previously describedcomposition were obtained. Incidentally, the A1 point of the base metalsheets was 727° C.

In the hot rolling, the ingots each having a thickness of 230 mm heatedto 1000° C. were thinned down to a thickness of 50 mm, and hot-rolledsheets were obtained. Sheet materials having various thicknesses werecut out from these hot-rolled sheets by machining and then weresubjected to the cold rolling, and thereby cold-rolled sheets eachhaving a thickness of 8 μm to 750 μm (the base metal sheets) wereobtained.

Incidentally, the main phase of each of the base metal sheets at roomtemperature was an α-Fe phase and as a result of measurement, the A3point at which the α-γ transformation occurred was 911° C. Further, atexture in the α-Fe phase of each of the base metal sheets was measuredby X-ray diffraction, and by the previously described method, anaccumulation degree of {200} planes and an accumulation degree of {222}planes were obtained. Further, as a result that up to the cold rollingwas performed, it was confirmed that of each of the base metal sheets,the accumulation degree of the {200} planes is 20 to 26% and theaccumulation degree of the {222} planes is 18 to 24%.

Next, these base metal sheets were subjected to decarburizationannealing so that a decarburized depth (a distance x) might become 1 μmto 59 μm. A decarburization condition was set that the temperature is800° C. and the decarburization time is 0.05 minutes to 550 minutes.With regard to the atmosphere during the decarburization annealing, astrong decarburizing atmosphere was applied in the case of thedecarburization annealing being performed for one minute or shorter, andin the case of the decarburization annealing being performed for longerthan one minute, a weak decarburizing atmosphere was applied in thefirst half of the decarburization annealing and a strong decarburizingatmosphere was applied in the second half of the decarburizationannealing.

Then, after the decarburization annealing was performed, thedecarburized depth and the C content of a decarburized region weremeasured and a structure and a crystal orientation of a surface layerwere examined. The measurement of the crystal orientation was performedby the method using the previously described X-ray diffraction method,the X-ray was emitted from the surface, and the accumulation degree ofthe {200} planes in the α-Fe phase was obtained.

After the decarburization annealing, both surfaces of each of the basemetal sheets were coated with Al as the second layer by an ion platingmethod (hereinafter, an IP method) to each have a thickness of 1 μm.

Next, an experiment was performed in which a heat treatment wasperformed on the base metal sheets to each of which the second layerswas bonded under various conditions. A gold image furnace was used forthe heat treatment, and a temperature increasing rate, a holdingtemperature, and a holding time were variously controlled by programcontrol. During which the temperature increased to be held, the heattreatment was performed in an atmosphere vacuumed to a pressure of 10⁻³Pa level. At the time of cooling, in the case of a cooling rate of 1°C./sec or lower, temperature control was performed in a vacuum byfurnace output control. Further, in the case of the cooling rate of 10°C./sec or more, an Ar gas was introduced and the cooling rate wascontrolled by adjustment of its flow rate.

Further, the observation of the texture in this period was alsoperformed by the same method described in Example 1. Further,magnetometry was performed in the same manner as that in Example 1 inorder to evaluate obtained products, and further the Z value wascalculated by the X-ray diffraction.

Further, an alloyed ratio in the second layer and a ratio of the αsingle phase region were defined and obtained as follows.

Plane distribution of the Fe content and plane distribution of the Alcontent were measured by using an EPMA (Electron Probe Micro-Analysis)method, with a field of view of an L direction 1 mm×the total thicknessin an L cross section. First, as the alloyed ratio in the second layer,areas of a region satisfying Fe≦mass % and Al≧99.5 mass % before andafter the heat treatment were obtained. Then, the alloyed ratio of thesecond layer was defined as (S₀−S)/S₀×100, where an area when Al wasapplied and the heat treatment was not performed was set to S₀ and anarea in the Fe-based metal sheet on which the whole heat treatment wascompleted was set to S.

Further, the ratio of the α single phase region was defined as(T/T₀)×100, where an area of a cross section of the Fe-based metal sheetafter the heat treatment, observed in the L cross section was set to T₀and an area of a diffused region of the different metal after the heattreatment was set to T. Incidentally, when the second layer was Al, anarea of a region satisfying Al≧0.9 mass % was set to T.

Table 8 shows the base metal sheets and conditions of thedecarburization and the heat treatment, and shows the accumulationdegrees of the {200} planes and the accumulation degrees of the {200}planes measured during the manufacture (after the decarburizationannealing) and after the manufacture (after the diffusion treatment),the Z values of the obtained Fe-based metal sheets, the alloyed ratiosof the second layers, and evaluation results of the magnetometry.

TABLE 8 C CONTENT BASE DECARBU- DECARBU- DECARBU- AFTER MATERIAL SHEETDECARBU- RIZATION RIZATION RIZED DECARBU- C CONTENT THICKNESS RIZINGTEMPERATURE TIME REGION RIZATION No. mass % μm ATMOSPHERE ° C. MINUTE μmmass % 201 0.050 10 STRONG 800 1 9 0.010 202 0.050 100 WEAK + STRONG 8003 12 0.011 203 0.050 250 WEAK + STRONG 800 5 14 0.015 204 0.050 500WEAK + STRONG 800 15 22 0.018 205 0.050 750 WEAK + STRONG 800 30 310.018 206 0.050 100 STRONG 800 0.1 6 0.008 207 0.050 100 WEAK + STRONG800 250 36 0.017 208 0.050 500 WEAK + STRONG 800 550 49 0.017 209 0.050200 WEAK + STRONG 800 10 18 0.008 210 0.050 200 WEAK + STRONG 800 10 180.009 211 0.050 200 WEAK + STRONG 800 10 19 0.008 212 0.050 200 WEAK +STRONG 800 10 18 0.010 213 0.050 200 WEAK + STRONG 800 10 17 0.008 2140.050 200 WEAK + STRONG 800 10 18 0.009 215 0.050 200 WEAK + STRONG 80010 18 0.009 216 0.050 200 WEAK + STRONG 800 10 16 0.010 217 0.050 150WEAK + STRONG 800 8 15 0.007 218 0.050 150 WEAK + STRONG 800 8 14 0.006219 0.050 150 WEAK + STRONG 800 8 16 0.007 220 0.050 150 WEAK + STRONG800 8 14 0.007 221 0.050 150 WEAK + STRONG 800 8 14 0.007 222 0.050 150WEAK + STRONG 800 8 15 0.007 223 0.050 150 WEAK + STRONG 800 8 16 0.006224 0.050 300 WEAK + STRONG 800 15 21 0.011 225 0.050 300 WEAK + STRONG800 15 22 0.009 226 0.050 300 WEAK + STRONG 800 15 22 0.009 227 0.050 8STRONG 800 1 8 0.010 228 0.050 100 STRONG 800 0.05 1 0.050 229 0.050 100WEAK + STRONG 800 60 59 0.003 230 0.050 100 WEAK + STRONG 800 18 230.010 231 0.050 100 WEAK + STRONG 800 18 25 0.011 232 0.050 100 WEAK +STRONG 800 18 26 0.009 233 0.050 100 WEAK + STRONG 800 18 25 0.009 2340.050 100 WEAK + STRONG 800 18 24 0.010 235 0.050 100 WEAK + STRONG 80018 26 0.009 ACCUMULATION DEGREE TEMPERATURE OF {200} FERRITE- INCREASINGHOLDING HOLDING COOLING PLANES AFTER FORMING RATE TEMPERATURE TIME RATE(S₀ − S)/ No. DECARBURIZATION ELEMENT ° C./sec T1 ° C. MINUTE ° C./secS₀ × 100 201 26 Al 0.5 1000 5 100 79 202 24 Al 0.5 1000 5 100 65 203 25Al 0.5 1000 5 100 52 204 21 Al 0.5 1000 5 100 39 205 29 Al 0.5 1000 5100 37 206 23 Al 0.5 1000 5 100 66 207 26 Al 0.5 1000 5 100 64 208 38 Al0.5 1000 5 100 31 209 26 Al 0.1 950 1 100 61 210 27 Al 1 1000 1 100 59211 26 Al 5 1000 5 100 62 212 25 Al 10 1000 5 100 60 213 26 Al 20 1000 5100 58 214 26 Al 0.5 950 5 100 59 215 27 Al 0.5 1050 5 100 60 216 25 Al0.5 1200 5 100 57 217 28 Al 0.5 1000 0.5 100 29 218 29 Al 0.5 1000 10100 61 219 30 Al 0.5 1000 30 100 76 220 29 Al 0.5 1000 60 100 81 221 29Al 0.5 1000 120 100 96 222 28 Al 0.5 1000 550 100 100 223 30 Al 0.5 10004500 100 100 224 22 Al 0.5 1000 10 0.1 79 225 21 Al 0.5 1000 10 10 51226 22 Al 0.5 1000 10 450 55 227 26 Al 0.5 950 1 100 100 228 17 Al 0.51000 10 100 65 229 28 Al 0.5 1000 10 100 62 230 26 NONE 0.5 1000 10 1000 231 24 Al 0.5 900 10 100 46 232 27 Al 0.5 1350 10 100 78 233 23 Al 0.51000 6000 100 100 234 25 Al 0.5 1000 10 0.05 85 235 28 Al 0.5 1000 10550 34 ACCUMULATION ACCUMULATION DEGREE OF DEGREE OF {200} PLANES {222}PLANES B50/Bs T/T₀ × AFTER AFTER OF ΔB No. 100 DIFFUSION DIFFUSION ZPRODUCT T NOTE 201 64 54 16 124  0.892 0.042 INVENTION EXAMPLE 201 20250 42 28 56 0.864 0.057 INVENTION EXAMPLE 202 203 43 36 24   8.9 0.8420.098 INVENTION EXAMPLE 203 204 32 36 20 11 0.852 0.091 INVENTIONEXAMPLE 204 205 30 37 22 15 0.859 0.085 INVENTION EXAMPLE 205 206 49 4624 69 0.893 0.042 INVENTION EXAMPLE 206 207 44 41 22 42 0.865 0.054INVENTION EXAMPLE 207 208 26 32 27   3.1 0.833 0.101 INVENTION EXAMPLE208 209 50 41 23 39 0.859 0.083 INVENTION EXAMPLE 209 210 48 39 26 250.865 0.071 INVENTION EXAMPLE 210 211 51 42 18 68 0.872 0.045 INVENTIONEXAMPLE 211 212 46 34 25   4.3 0.851 0.096 INVENTION EXAMPLE 212 213 5049 11 76 0.897 0.038 INVENTION EXAMPLE 213 214 48 36 23 16 0.845 0.084INVENTION EXAMPLE 214 215 44 48 18 82 0.896 0.021 INVENTION EXAMPLE 215216 46 60 9 148  0.904 0.016 INVENTION EXAMPLE 216 217 24 34 24   3.50.835 0.115 INVENTION EXAMPLE 217 218 47 73 6 175  0.953 0.008 INVENTIONEXAMPLE 218 219 55 62 11 152  0.913 0.011 INVENTION EXAMPLE 219 220 6858 14 135  0.901 0.018 INVENTION EXAMPLE 220 221 75 52 15 112  0.8990.021 INVENTION EXAMPLE 221 222 74 59 10 139  0.908 0.016 INVENTIONEXAMPLE 222 223 76 55 12 131  0.895 0.018 INVENTION EXAMPLE 223 224 6463 8 162  0.918 0.011 INVENTION EXAMPLE 224 225 43 72 4 189  0.958 0.007INVENTION EXAMPLE 225 226 37 68 6 158  0.954 0.009 INVENTION EXAMPLE 226227 100 18 31   0.3 0.789 0.108 COMPARATIVE EXAMPLE 201 228 41 24 37  1.2 0.785 0.110 COMPARATIVE EXAMPLE 202 229 38 37 24 19 0.857 0.086INVENTION EXAMPLE 227 230 0 19 31   1.4 0.778 0.105 COMPARATIVE EXAMPLE203 231 37 22 27   0.9 0.768 0.104 COMPARATIVE EXAMPLE 204 232 51 38 2014 0.832 0.095 INVENTION EXAMPLE 228 233 76 38 26 17 0.842 0.091INVENTION EXAMPLE 229 234 70 37 25 16 0.845 0.089 INVENTION EXAMPLE 230235 27 38 26 15 0.841 0.089 INVENTION EXAMPLE 231

As shown in Table 8, in each of present invention examples, it waspossible to confirm that the magnetic flux density difference ΔB becomesa small value as compared to comparative examples and a high magneticflux density can be obtained thoroughly in the in-plane circumferentialdirection. Further, in these Fe-based metal sheets, it was possible toconfirm that an excellent magnetic property in which the value of B50/Bsis 0.80 or more is obtained.

Further, in the present invention examples, it was possible to confirmthat the alloyed ratio and the ratio of the α single phase region can becontrolled by the combination of the decarburized depth of the basemetal sheet, the temperature increasing rate, the holding temperatureafter the heating, and the holding time, and the Fe-based metal sheethaving an excellent magnetic property can be obtained.

Further, an L cross section of each of the present invention exampleswas observed, and thereby it was confirmed that the α single phaseregion made of the α single phase based component exists in at least apartial region including the surfaces and the ratio of the α singlephase region to the L cross section is 1% or more.

In contrast to this, for example, in the case of the insufficientdecarburized region as in a comparative example 201, in the case ofusing no metal for the second layer as in a comparative example 203, andin the case of not heating to a temperature of the A3 point or higher asin a comparative example 204, it was not possible to obtain a highmagnetic flux density in the in-plane circumferential directionthoroughly as in the present invention examples. Further, even when thetemperature was increased to a higher temperature and the holding timewas made longer as in present invention examples 228 and 229, thesimilar effect was able to be obtained, but the significant effect didnot appear.

Example 4

In this example, as the ferrite-forming element, Sn, Al, Si, Ti, Ga, Ge,Mo, V, Cr, or As was applied to the second layer, and the relationshipbetween the case where demanganization was performed in addition todecarburization and an accumulation degree of {200} planes was examined.

First, base metal sheets containing six types of components F to K shownin Table 9 below and having a balance being composed of Fe andinevitable impurities were prepared. Ingots were each melted by vacuummelting to then be worked to a predetermined thickness by hot rollingand cold rolling, and the above-described base metal sheets wereobtained. Incidentally, the A1 point of each of these base metal sheetswas 727° C.

TABLE 9 (MASS %) STEEL Ar3 POINT TYPE ° C. C Si Mn Al P N S O F 877 0.030.05 0.15 0.0005 0.0001 0.0002 <0.0004 0.0002 G 880 0.03 0.10 0.250.0004 0.0002 0.0001 <0.0005 0.0001 H 867 0.05 0.05 1.00 0.0003 0.00010.0002 <0.0004 0.0002 I 771 0.50 0.1 0.30 0.0004 0.0002 0.0002 <0.00040.0002 J 773 0.80 1.00 0.12 0.0030 0.0020 0.0001 <0.003 0.0001 K 8590.10 0.30 1.50 0.0030 0.0020 0.0001 <0.003 0.0002

In the hot rolling, the ingots each having a thickness of 230 mm wereheated to 1000° C. to be thinned down to a thickness of 50 mm, andhot-rolled sheets were obtained. Then, sheet materials having variousthicknesses were cut out from these hot-rolled sheets by machining tothen be subjected to the cold rolling, and the base metal sheets eachhaving a thickness falling within a range of 10 μm to 750 μm weremanufactured.

At this time, the main phase of each of the obtained base metal sheetsat room temperature was an α-Fe phase. Further, as a result ofmeasurement, the A3 point at which the α-γ transformation occurred wastemperatures shown in Table 9. Further, by X-ray diffraction, a texturein the α-Fe phase of each of the base metal sheets was measured, and bythe previously described method, an accumulation degree of {200} planesand an accumulation degree of {222} planes were obtained. As a result,it was confirmed that at the stage of completion of the cold rolling, ofeach of the base metal sheets, the accumulation degree of the {200}planes was 19 to 27% and the accumulation degree of the {222} planes was18 to 25%.

Next, these base metal sheets after this cold rolling each had amaterial promoting decarburization, or a material promotingdecarburization and a material promoting demanganization applied theretoas an annealing separating agent, and were subjected to tight coilannealing or stacked annealing. At this time, the annealing wasperformed so that depths of the decarburization and the demanganizationmight become not less than 1 μm nor more than 49 μm. As conditions ofthe annealing, the temperature was set to 700° C. to 900° C. and theannealing was performed in a reduced pressure atmosphere. Further, astructure and a crystal orientation of a surface layer after completionof the decarburization annealing or the decarburization anddemanganization annealing were examined. The measurement of the crystalorientation was performed by the X-ray diffraction method, and theaccumulation degree of the {200} planes in the α-Fe phase and theaccumulation degree of the {222} planes in the α-Fe phase were obtained.

Next, with respect to each of the base metal sheets after thedecarburization annealing or the decarburization and demanganizationannealing, both surfaces of each of the base metal sheets were coatedwith the different metal by using an IP method, a hot dipping method, ora sputtering method to have a thickness of 10 μm in total.

Subsequently, a heat treatment was performed under various conditions bythe same method as that used in Example 3, and an experiment wasperformed in which the state in each of the processes during themanufacture was evaluated. An alloyed ratio of the second layer wasdefined as (S₀−S)/S₀×100 similarly to Example 3, and assuming that ametal element of the second layer was [M], an area of a regionsatisfying Fe≦0.5 mass % and [M]≧99.5 mass % was obtained, which wasapplied to any one of the elements.

On the other hand, a ratio of the α single phase region was alsoobtained by the same procedure as that in Example 3. However, when thesecond layer was Sn, T was obtained from an area of a region satisfyingSn≧3.0 mass %, and similarly, in the case of Al, it was obtained from anarea of a region satisfying Al≧0.9 mass %. Further, in the case of Si,it was obtained from an area of a region satisfying Si≧1.9 mass %, andin the case of Ti, it was obtained from an area of a region satisfyingTi≧3.0 mass %. Similarly, in the case of Ga, it was obtained from anarea of a region satisfying Ga≧4.1 mass %, in the case of Ge, it wasobtained from a region satisfying Ge≧6.4 mass %, in the case of Mo, itwas obtained from a region satisfying Mo≧3.8 mass %, in the case of V,it was obtained from a region satisfying V≧1.8 mass %, in the case ofCr, it was obtained from a region satisfying Cr≧14.3 mass %, and in thecase of As, it was obtained from an area of a region satisfying As≧3.4mass %.

Table 10 and Table 11 show the base metal sheets and conditions of theheat treatment such as the decarburization, and show the accumulationdegrees of the {200} planes and the accumulation degrees of the {222}planes measured during the manufacture (after thedecarburization•demanganization annealing) and after the manufacture(after the diffusion treatment), the Z values of the obtained Fe-basedmetal sheets, the alloyed ratios of the second layers, and evaluationresults of the magnetometry.

TABLE 10 DECARBURIZATION AND DECARBURIZED BASE DEMANGANIZATION AND CCONTENT TEMPERATURE MATERIAL SHEET ANNEALING DEMANGANIZED AFTER FERRITE-INCREASING STEEL THICKNESS TEMPERATURE REGION DECARBURIZATION FORMINGRATE No. TYPE μm ° C. μm mass % ELEMENT ° C./sec 236 F 150 800 21 0.008Sn 0.5 237 G 150 800 26 0.010 Sn 0.5 238 H 150 800 23 0.009 Sn 0.5 239 I150 800 24 0.011 Sn 0.5 240 J 150 800 21 0.009 Sn 0.5 241 K 150 800 260.009 Sn 0.5 242 F 10 800 4 0.010 Al 0.5 243 F 100 800 12 0.011 Al 0.5244 F 250 800 14 0.015 Al 0.5 245 F 500 800 22 0.018 Al 0.5 246 F 750800 31 0.018 Al 0.5 247 G 150 700 10 0.008 Al 0.5 248 C 150 900 24 0.017Al 0.5 249 H 200 800 49 0.017 Al 0.5 250 H 200 800 6 0.014 Al 0.5 251 I100 800 14 0.006 Al 0.5 252 I 100 800 15 0.014 Si 0.5 253 I 100 800 150.014 Zn 0.5 254 I 200 800 18 0.008 Ti 0.5 255 I 200 800 18 0.009 Ga 0.5256 I 200 800 19 0.008 Ge 0.5 257 I 200 800 18 0.010 Ho 0.5 258 I 200800 17 0.008 V 0.5 259 I 200 800 18 0.009 Cr 0.5 260 I 200 800 18 0.009As 0.5 261 J 200 800 16 0.010 Al 0.1 262 J 150 800 15 0.007 Al 1ACCUMULATION ACCUMULATION ACCUMULATION DEGREE OF DEGREE OF DEGREE OFHOLDING HOLDING COOLING {200} PLANES {222} PLANES {200} PLANESTEMPERATURE TIME RATE AFTER AFTER AFTER No. T1 ° C. MINUTE ° C./secANNEALING ANNEALING} DIFFUSION 236 1000 5 100 36 21 61 237 1000 5 100 3425 68 238 1000 5 100 33 21 65 239 1000 5 100 35 23 71 240 1000 5 100 3721 59 241 1000 5 100 34 18 60 242 1000 5 100 35 21 47 243 1000 5 100 3424 49 244 1000 5 100 35 18 51 245 1000 5 100 31 26 44 246 1000 5 100 3922 40 247 1000 5 100 24 26 46 248 1000 5 100 36 18 68 249 1000 5 100 3827 72 250 1000 5 100 23 20 39 251 1000 5 100 29 16 40 252 1000 5 100 3424 46 253 1000 5 100 33 26 51 254 1000 5 100 36 22 49 255 1000 5 100 3724 56 256 1000 5 100 36 23 55 257 1000 5 100 35 26 61 258 1000 5 100 3619 48 259 1000 5 100 36 28 60 260 1000 5 100 37 15 53 261 1000 5 100 3522 57 262 1000 5 100 38 17 61 ACCUMULATION DEGREE OF {222} PLANES AFTER(S0 − S)/ B50/Bs No. DIFFUSION S0 × 100 T/T0 × 100 Z OF PRODUCT ΔB TNOTE 236 14 66 38 126 0.921 0.021 INVENTION EXAMPLE 232 237 12 64 33 1350.942 0.034 INVENTION EXAMPLE 233 238 13 59 36 129 0.937 0.037 INVENTIONEXAMPLE 234 239 8 61 37 187 0.963 0.007 INVENTION EXAMPLE 235 240 17 6534 113 0.921 0.048 INVENTION EXAMPLE 236 241 12 63 35 123 0.917 0.042INVENTION EXAMPLE 237 242 17 79 64 64 0.884 0.069 INVENTION EXAMPLE 238243 13 65 50 56 0.879 0.072 INVENTION EXAMPLE 239 244 11 52 43 63 0.8920.062 INVENTION EXAMPLE 240 245 19 39 32 52 0.876 0.075 INVENTIONEXAMPLE 241 246 18 37 30 23 0.857 0.086 INVENTION EXAMPLE 242 247 14 6649 35 0.872 0.082 INVENTION EXAMPLE 243 248 9 64 44 142 0.924 0.027INVENTION EXAMPLE 244 249 4 31 26 167 0.947 0.011 INVENTION EXAMPLE 245250 15 68 57 5.4 0.853 0.101 INVENTION EXAMPLE 246 251 17 69 59 28 0.8670.087 INVENTION EXAMPLE 247 252 16 66 54 37 0.879 0.083 INVENTIONEXAMPLE 248 253 13 67 56 67 0.896 0.067 INVENTION EXAMPLE 249 254 19 6150 29 0.887 0.076 INVENTION EXAMPLE 250 255 8 59 48 121 0.897 0.031INVENTION EXAMPLE 251 256 8 62 51 116 0.916 0.036 INVENTION EXAMPLE 252257 6 60 46 129 0.916 0.026 INVENTION EXAMPLE 253 258 17 58 50 59 0.8970.068 INVENTION EXAMPLE 254 259 9 59 48 129 0.906 0.039 INVENTIONEXAMPLE 255 260 11 60 44 119 0.899 0.042 INVENTION EXAMPLE 256 261 10 5746 125 0.914 0.029 INVENTION EXAMPLE 257 262 9 29 24 131 0.916 0.013INVENTION EXAMPLE 258

TABLE 11 DECARBURIZATION AND DECARBURIZED BASE DEMANGANIZATION AND CCONTENT TEMPERATURE MATERIAL SHEET ANNEALING DEMANGANIZED AFTER FERRITE-INCREASING STEEL THICKNESS TEMPERATURE REGION DECARBURIZATION FORMINGRATE TYPE μm ° C. μm mass % ELEMENT ° C./sec 263 J 150 800 14 0.006 Al 5264 J 150 800 16 0.007 Al 10 265 J 150 800 14 0.007 Al 20 266 K 150 80014 0.007 Al 0.5 267 K 150 800 15 0.007 Al 0.5 268 K 150 800 16 0.006 Al0.5 269 K 300 800 21 0.011 Al 0.5 270 K 300 800 22 0.009 Al 0.5 271 K300 800 22 0.009 Al 0.5 272 K 300 800 21 0.008 Al 0.5 273 K 300 800 230.009 Al 0.5 274 K 300 800 21 0.008 Al 0.5 275 G 300 800 21 0.008 Al 0.5276 G 300 800 21 0.008 Al 1.5 277 G 300 800 21 0.008 Al 2.5 278 F 8 8008 0.010 Al 0.5 279 G 100 650 21 0.050 Al 0.5 280 G 100 950 41 0.003 Al0.5 281 H 100 800 1 0.010 Al 0.5 282 H 200 900 69 0.011 Al 0.5 283 K 100800 26 0.009 NONE 0.5 284 I 100 800 25 0.009 Al 0.5 285 I 100 800 240.010 Al 0.5 286 J 100 800 26 0.009 Al 0.5 287 J 100 800 24 0.008 Al 0.5288 J 100 800 26 0.010 Al 0.5 ACCUMULATION ACCUMULATION ACCUMULATIONDEGREE OF DEGREE OF DEGREE OF HOLDING HOLDING COOLING {200} PLANES {222}PLANES {200} PLANES TEMPERATURE TIME RATE AFTER AFTER AFTER T1 ° C.MINUTE ° C./sec ANNEALING ANNEALING DIFFUSION 263 1000 5 100 39 23 75264 1000 5 100 30 19 42 265 1000 5 100 29 14 38 266 950 5 100 29 24 40267 1250 5 100 28 23 36 268 1000 0.5 100 30 25 67 269 1000 10 100 22 2943 270 1000 30 100 21 30 41 271 1000 60 100 22 28 38 272 1000 120 100 2821 64 273 1000 550 100 27 19 73 274 1000 4500 100 22 31 79 275 1000 50.1 29 25 51 276 1000 5 10 26 24 52 277 1000 5 450 24 25 45 278 950 1100 26 23 47 279 1000 10 100 17 19 21 280 1000 10 100 14 14 19 281 100010 100 11 24 23 282 1000 10 100 24 23 57 283 1000 10 100 27 25 12 284765 10 100 23 29 25 285 1350 10 100 25 16 48 286 1000 6050 100 28 24 46287 1000 10 0.05 22 26 38 288 1000 10 500 26 22 39 ACCUMULATION DEGREEOF {222} PLANES AFTER (S0 − S)/ B50/Bs DIFFUSION) S0 × 100 T/T0 × 100 ZOF PRODUCT ΔB T NOTE 263 7 61 47 189  0.975 0.006 INVENTION EXAMPLE 259264 16 76 55 43 0.864 0.064 INVENTION EXAMPLE 260 265 16 81 68 16 0.8460.098 INVENTION EXAMPLE 261 266 11 96 75 21 0.853 0.092 INVENTIONEXAMPLE 262 267 17 100 74   8.3 0.839 0.103 INVENTION EXAMPLE 263 268 7100 76 164  0.943 0.010 INVENTION EXAMPLE 264 269 15 79 64 53 0.8720.059 INVENTION EXAMPLE 265 270 18 51 43 43 0.867 0.063 INVENTIONEXAMPLE 266 271 16 55 37 12 0.843 0.096 INVENTION EXAMPLE 267 272 5 5634 158  0.929 0.009 INVENTION EXAMPLE 268 273 3 53 38 168  0.968 0.007INVENTION EXAMPLE 269 274 7 55 42 198  0.978 0.005 INVENTION EXAMPLE 270275 4 54 38 123  0.895 0.036 INVENTION EXAMPLE 271 276 6 51 44 128 0.896 0.034 INVENTION EXAMPLE 272 277 12 53 31 73 0.879 0.053 INVENTIONEXAMPLE 273 278 19 100 100 86 0.876 0.049 INVENTION EXAMPLE 274 279 2865 41   1.3 0.778 0.123 COMPARATIVE EXAMPLE 205 280 22 62 38   0.8 0.7790.113 COMPARATIVE EXAMPLE 206 281 14 66 31   0.9 0.782 0.109 COMPARATIVEEXAMPLE 207 282 18 61 37 135  0.905 0.037 INVENTION EXAMPLE 275 283 11 00   0.6 0.765 0.096 COMPARATIVE EXAMPLE 208 284 31 57 21   1.2 0.7860.109 COMPARATIVE EXAMPLE 209 285 22 85 70 68 0.875 0.052 INVENTIONEXAMPLE 276 286 15 92 73 63 0.881 0.054 INVENTION EXAMPLE 277 287 17 8469 12 0.852 0.089 INVENTION EXAMPLE 278 288 16 63 31 21 0.859 0.086INVENTION EXAMPLE 279

In each of present invention examples, it was possible to confirm thatthe magnetic flux density difference ΔB becomes a small value ascompared to comparative examples and a high magnetic flux density isobtained thoroughly in the in-plane circumferential direction. Further,in these Fe-based metal sheets, it was possible to confirm that anexcellent magnetic property in which the value of B50/Bs is 0.80 or moreis obtained.

Further, in the present invention examples, as shown in Table 10 andTable 11, it was possible to confirm that the {200} plane in the α-Fephase is likely to be highly accumulated at each of the stages of theheat treatment.

Further, an L cross section of each of the present invention exampleswas observed, and thereby it was confirmed that the α single phaseregion made of the α single phase based component exists in at least apartial region including the surfaces and the ratio of the α singlephase region to the L cross section is 1% or more.

In contrast to this, for example, in the case of the insufficientdecarburized and demanganized region as in a comparative example 207, inthe case of using no metal for the second layer as in a comparativeexample 208, and in the case of not heating to a temperature of the A3point or higher as in a comparative example 209, it was not possible toobtain a high magnetic flux density in the in-plane circumferentialdirection thoroughly as in the present invention examples, andconsequently, an obtained magnetic property was also poor. Even when thetemperature was increased to a higher temperature and the holding timewas made longer as in present invention examples 276 and 277, thesimilar effect was able to be obtained, but the significant effect didnot appear.

In the foregoing, the preferred embodiments of the present inventionhave been described in detail, but the present invention is not limitedto such examples. It is apparent that a person having common knowledgein the technical field to which the present invention belongs is able todevise various variation or modification examples within the range oftechnical ideas of the present invention, and it should be understoodthat they also belong to the technical scope of the present invention asa matter of course.

Industrial Applicability

The Fe-based metal sheet of the present invention is suitable formagnetic cores and the like of transformers and the like using a siliconsteel sheet, and can contribute to downsizing of these magnetic coresand reduction in energy loss.

The invention claimed:
 1. An Fe-based metal sheet, comprising: less than0.2 mass % C and having a composition that is capable of causing an α-γtransformation, wherein a ferrite-forming element, being one element ormore selected from the group consisting of Al, Mo, Ga, Sn, Ti, Ge, Sb,V, W, Zn and As is alloyed on a partial or whole region of the Fe-basedmetal sheet, and when intensity ratios of respective {001}<470>, {116}<612 1>, and {223}<692>directions in a sheet plane by X-ray diffractionare set to A, B, and C respectively and Z=(A +0.97B)/0.98C is satisfied,a Z value is not less than 2.0 nor more than 200; wherein at least apartial region including surfaces of the Fe-based metal sheet is an αsingle phase region that is alloyed with said ferrite-forming element,and a ratio of the α single phase region to a cross section of theFe-based metal sheet is 1% or more, wherein an accumulation degree of{200} planes is not less than 30% nor more than 99%, and an accumulationdegree of {222} planes is not less than 0.01% nor more than 30%, andsaid accumulation degree of {200} planes is expressed by Expression (1)below and said accumulation degree of {222} planes is expressed byExpression (2) below,accumulation degree of {200}planes=[{i(200)/I(200)}/Σ{i(hkl)/I(hkl)}]×100  (1)accumulation degree of {222}planes=[{i(222)/I(222)}/Σ{i(hkl)/I(hkl)}]×100  (2) wherein i (hkl) is anactually measured integrated intensity of {hkl} planes in the surface ofthe Fe-based metal sheet, and I (hkl) is a theoretical intergratedintensity of the {hkl} planes in a sample having a random orientation,and 11 kinds of planes of {110}, {200}, {211}, {310}, {222}, {321},{411}, {420}, {332}, {521}, and {442} are used as the {hkl} planes. 2.The Fe-based metal sheet according to claim 1, wherein a layercontaining said ferrite-forming element is formed on at least one sideof surfaces of the Fe-based metal sheet, and said ferrite-formingelement that has diffused from part of the layer is alloyed with Fe. 3.The Fe-based metal sheet according to claim 2, wherein a thickness ofthe layer containing said ferrite-forming element is not less than 0.01μm nor more than 500 μM.
 4. The Fe-based metal sheet according to claim1, wherein a thickness of the Fe-based metal sheet is not less than 10μm nor more than 6 mm.
 5. The Fe-based metal sheet according to claim 1,wherein the α single phase region is formed on a front surface side anda rear surface side of the Fe-based metal sheet, and a crystal grainstraddling the a single phase region on the front surface side and the αsingle phase region on the rear surface side is formed.